SICK Magazine

01 2007 www.sick.
com
Dynamic safety
Safe complete solution ideally
implemented at MTU
Page 8
RFID at Hfele
RFID system controls SOP
at fittings producer Hfele
Page 12
Technological lead
Optical distance sensors
for optimum solutions
Page 35
S I C K S C U S T O M E R M A G A Z I N E
A new masterpiece in distance sensors: the DS30
Page 41
The very best
The very best
1/2007 03
: Editorial
Dear Reader,
SICK Belgium was founded 20 years ago, we have been booking
double-figure growth for the last ten years, and we now have 28 employ-
ees, a leading market position, and are ideally equipped to meet future
challenges.
This success has been made possible by the products which allowed us
to solve a wide variety of tasks, and our consistent customer orientation.
The Eurologistics link with the works in Waldkirch was set up very early
and, for over a decade, has guaranteed maximum delivery reliability. We
work intensively on optimising Customer Relation Management, which
ensures optimum customer support and the smooth processing of or-
ders. The international issue of SICK insight has become an important
instrument for gaining and retaining customers. Today we are proud
of supplying more than 1,500 regular customers per year machine
producers, system integrators and end-users.
Change will be the only constant in future. We are already actively
thinking about what tomorrows market will need. Customer satisfaction
remains our benchmark.
I wish you a good read in this latest issue of
SICKs customer magazine.
Best wishes
Bernard Lejour
Managing Director, SICK Belgium
insightTELEGRAM
++ Bosch Rexroth and SICK form tech-
nical co-operation in factory automation
aim of co-operation: system solutions
that can be easily and flexibly integrated
control systems from the automation
company Bosch Rexroth with SICK sen-
sors permit users to save time, simplify
integration through open standards and
co-ordinate interfaces with one another
++ SICK AG wins special Equal Oppor-
tunities prize in February for exem-
plary processes in promoting employees
regardless of age and gender, and for
companys family orientation 198
companies participated in Germanys
best employers competition SICK AG
took seventh place overall
www.greatplacetowork.de ++
In the last issue (2.2006), we regret that a mis-
take crept into the picture heading on Page 30.
The correct version: safetyPLUS was used for a
newly implemented project at KUKA Schweissan-
lagen GmbH
: Contents
04
1/2007
07
OSMA lifts rely on the DKS40
incremental encoder from SICK
26
EN ISO 13849-1 and EN 62061 Dr. Michael
Schaefer and Michael Hauke in interview
38
Time-of-flights time has come more highly
sophisticated distance sensor
41 :

T
I
T
L
E

T
O
P
I
C
Volume measurement and identification as po-
tentially approved-for-trade package solution
: Interview
Nothing to fear from standards duo .... 38
: HMI Special .................. 40
: Products
TITLE TOPIC
Time-of-flights time has come ........... 41
Product News ...................................... 42
When safety logic
manages without software ................ 44
Bluetooth hand-held scanner
for industrial use ................................. 45
3D smart camera for
picking systems and robots .................. 46
Safety light curtain in
specific variants .................................. 47
Efficient, despite difficult contrasts ... 48
The new-generation
hand-held bar code reader ................. 49
Now also for C-slots ............................ 49
First automation light
curtain with IO-Link .............................. 50
Remote teach-in and diagnosis .......... 51
Space-saving scanner ......................... 52
New HIPERFACE
adapter modules .... 52

Safety switches:
product portfolio grows further .......... 53
New 3D smart camera ........................ 54
IP 67 safety controller ........................ 55
All-round innovation and individuality ... 55
S300 Professional
safety laser scanner ............................ 56
: Museum
Birr Castle in the heart of Ireland ....... 57
: SICK Tour
SICK Robot Day 2007 ......................... 58
SICK optimises delivery reliability ...... 58
Through wild country unmanned .... 59
SICKs Partner Portal ........................... 59
Training 2007 ...................................... 60
Practical safetyPLUS
afternoons ...... 61
In overalls, all over .............................. 61
: Book Corner
How to get your point across
in 30 seconds or less ........................ 62
: Info
Imprint/Service ................................... 63
Trade fair dates ................................... 63
: Editorial ............................... 03
: Applications
Sensors get flat textile
products into shape ............................ 06
Revenue recovery at TNT Express ..... 07
Dynamic safety for articulated
shaft spraying plant ............................ 08
Perfect package detection .................. 09
Osterwalder AG relies on positioning
drive for powder presses .................... 10
Muting, not a test of courage ............. 11
RFID system at Hfele ........................ 12
Solution found for Findus
ready-to-serve meals .......................... 13
Access protection around the corners 14
2D code readers at
Johnson & Johnson ............................. 15
Processing checks on engine blocks .. 16
Sensor and control
modernisation on a coil press ............ 17
LMS400 in the spare parts store ....... 18
Diesel aggregate Nozzle inspection .... 19
Automatic sheet metal handling ........ 20
Safety and navigation via laser .......... 21
IVC-2D smart camera at Ford ............. 22
Safe automation .................................. 23
Wagons checked by laser ..................... 23
Vertical protection .................................. 24
Camera solution packed
with information .................................. 25
Lifts positioned at floor level ................ 26
Identification of articulated
shafts at MTU ...................................... 27
Distance sensors control
production of laminated beams ......... 28
Automatic position detection
for stage sets ....................................... 28
Omni-identification for
high-speed sorters .............................. 29
Color sensors hit the tape running ..... 30
HIPERFACE
-hype in
high-bay warehouse ............................ 31
: SICK MAIHAK
Measurement of bulk materials ......... 32
Rugged level measuring technique ... 33
: Technology
Optical distance sensors ..................... 34
The new DT20 Hi distance sensor ..... 35
Identification of the second dimension 36
Single-camera system for
2D and 3D image processing ............. 37
: News
05
>> Those who are in too much of a hurry
on motorways in the Swiss canton of
Vaud often make the acquaintance of
the motorway police. They have extreme-
ly helpful informers: speed monitoring
stations with integrated LMS laser meas-
urement systems from SICK tested
with sports cars!
Beware flashes when no photographer in sight
An expensive Good morning
from the motorway police
>> The tests were carried out in collabora-
tion with JohnsonDiversey in Mannheim.
The company is Europes market leader
for industrial cleaning and hygiene solu-
tions. JohnsonDiversey offers a consultan-
cy service for users and plant constructors
based on its comprehensive practical ex-
pertise in the food and beverages sector.
The W9-2 series of photoelectric
switches was the test victor. But other
opto-sensors, such as safety light curtains
in IP 67 protective housings, also demon-
strated a high level of material stability in
constant contact with alkaline, chlorine-
containing and oxidative products.
Opto-sensors survive strength tests
Certified material stability
At www.sick.com/insight you can find
out how constant use over five years is
simulated, whether the sensors are still
capable of functioning thereafter, and
why device stability in the field is not
solely dependent on the resistance of
the materials.
www.sick.com/insight INFO 101
A glance at the food industry
Milo Frank
How to get
your point across
in 30 seconds or less
A well-versed expert and trainer in communica-
tion techniques shows how you can learn to
forcefully present your point-of-view in half a
minute. A concise commentary on his book can
be found on Page 62.
insightBOOK CORNER
Current trade fairs with SICK
HANOVER TRADE FAIR AND INTERKAMA
+
in Hanover from 16 24 April 2007
Stand F54, Hall 9
www.hannovermesse.de
Control the international trade fair
for quality assurance
in Sinsheim from 8 11 May 2007
Stand 4104, Hall 4
www.control-messe.de
The monitoring systems are avail-
able either in the classic column form or
beautifully designed and (almost invis-
ibly) integrated in the crash barriers. The
accurate measurement results of the in-
tegrated LMS are of decisive important
for the reliability of the monitoring sys-
tems and the fine use of the images re-
corded. Not even sports car drivers have
a chance: while conventional radar traps
are too slow for speeds of over 250 km/h,
the LMS provides top-speed measure-
ment results even at 300 km/h.
20 systems are currently installed on
the motorway between Lausanne and
Geneva. But the speed monitoring sys-
tems, certified by Metav, also prove their
usefulness in urban areas about 40 sys-
tems are used in Zurich (with 80 systems
planned). www.cesag.com INFO 102
: Applications
1/2007 06
>> Textile folding machines from espri-
Tex GmbH allow a wide variety of folds
for presenting flat material products,
From a single source and available worldwide
Sensors get flat textile
products into shape
Whether sheets or blankets, pillow slips or towels, the textile folding machine
from the Swiss textile machine producer espriTex allows the correct folding of flat
material products. Whereby a variety of sensors from SICKs automation and safety
ranges ensure precise creases.
insightLINK
You can obtain further product
information with the attached card under:
INFO 103
or on the Internet at:
www.sick.com/insight/en
More about the customer:
www.espritex.biz
machine . The functions integrated in
the device, and the status information,
permit rapid commissioning and prevent
unnecessary machine downtimes.
Rotative, magnetic, opto-electronic:
automation sensors in folding
practice
A variety of automation sensors take
over important functions during the fold-
ing process. During each folding action,
the process starts at the same point and
takes the same path at a precisely calcu-
lated speed. The DKS40 incremental en-
coder extremely compact and particu-
larly robust ensures precise production
processes and thus the folding quality of
the flat textile products. The movement
and position of the various pneumatic
cylinders on the folding machine are
detected by MZT6 magnetic cylinders.
These can be inserted into all common
T-slots from above. This cuts the con-
struction and installation effort. A further
advantage: secure fixing. This guaran-
tees maximum reliability and switching
accuracy. espriTex relies on the VL180
cylindrical photoelectric reflex switch
for correctly identifying the flat material
products leaving the folding machine.
This device ensures that the flat textile
products are reliably detected on the
conveyor belt, regardless of the interplay
of colours or their shape.
Best folding processes replace wrin-
kles on the users forehead this com-
plete solution from SICK helps get the
flat textile products into shape.
The modular concept of the C2000 safety light curtain combines
machine safety and economic efficiency
The VL180 photoelectric reflex switch
detects flat textile products on the
conveyor belt
such as sheets, blankets, pillow slips
and towels. Depending on the folding
machine, up to 750 flat textile products
can be folded each hour, says Samuel
Gerber, Managing Director of espriTex.
Customers for the folding machines are
found worldwide. Which is why it was
so important for espriTexi that the au-
tomation and safety sensors were pur-
chased from a single source and would
be available to their customers all over
the world.
Finger safety during the
folding process
Folding takes place at a machine speed
of at least 500 mm/s, up to a maximum
of 1,000 mm/s. The mechanical folding
elements in the work process pose a risk
of injury for personnel. Which is why they
receive Category 2 protection from the
C2000 safety light curtain. The C2000s
modular concept combines machine
safety with economic efficiency, as the
device properties can be specifically
adapted to the needs of the folding
Samuel Gerber,
Managing Director of espriTex
Textile industry
: Applications
07
>> The improved performance capa-
bility, however, not only results in opti-
mised processes, but also offers the
possibility of charging each customer
for the number and volume of packages
actually transported. The system has
also resulted in improved sorting, prepa-
ration and distribution processes in the
depot, as well as better process reliabil-
ity, because each package has a unique
identity due to its bar code, its weight
and its dimensions so packages are
both controllable and traceable.
Invoicing actual
performance carried out
System components that can be cali-
brated are stipulated for so-called rev-
enue recovery, i.e. the possibility of cre-
ating follow-up invoices for the logistic
performance actually carried out. This
applies to the volume detection system
in addition to the scales. The VMS520
in the DWS system is a measurement
system that has been certified by the
Federal Institute of Physics and Technol-
Revenue recovery at TNT Express
Volume measurement and identification
as approved-for-trade package solution
TNT Express has equipped its depot in Neuss with a fully automatic DWS
(Dimensioning, Weighing and Scanning) system to increase productivity during
the processing of packages. The calibrated VMS520 volume measurement system
and the OPS490 omniportal reading system from SICK are operated as a package
solution.
ogy (PTB) in Braunschweig on the basis
of the testing parameters in the OIML
R129 standard. The scale value and the
calibration error limit are 0.5 cm each
related to a maximum transport speed
of 2 m/s. Objects with an edge length
from 50 mm upwards can be measured
with calibrated accuracy. It can thus be
used in combination with approved-for-
trade scales and bar code scanners in a
complete system capable of calibration.
Sorting control by omni-scanner
An OPS490 bar code reading portal has
been integrated in the DWS system to
identify the packages in the depot and to
control their destinations for the sorting
plant. In addition to an evaluation unit,
the system consists of several standard
scanners from the CLV490 series. The
scanner, with its integrated real-time
autofocus, generates a reading field of
800 x 800 mm
2
within which at least one
scanner can always read the bar code
label. The evaluation unit controls the
individual scanners reading activities,
insightLINK
INFO 104
www.tnt.de and www.tnt.com
processes the reading gate and path
information, and assigns the bar code
information to the particular object.
Up to 2,500 packages per hour
demands real-time communication
The VMS520, OPS490 and weighing sys-
tem transfer their data to the controller
of the entire system, and to the depots
IT host system, via Ethernet. So all the
relevant information for the sorting and
revenue recovery program is available
in real time even with high package
numbers.
The DWS system is not quite as
quickly amortised, but within a few
months through improved processes
in the depot, and the possibility of invoic-
ing the actual transport services provid-
ed and, if necessary, preparing follow-up
invoices.
All information of relevance to sorting
and revenue recovery is available in
real time Thomas Dzaeck (front) and
Gerhard Stensel from TNT Express
Package processing
: Applications
1/2007 08
>> As the market leader in safety technol-
ogy, SICK continues its integrated safety
thinking and activity with safetyPLUS
.
Those who know about safety do not
expect proprietary island solutions from
the supplier, but open and comprehen-
sive concepts; a high level of sensor,
control and application competence; as
well as the consideration of time-related
and global dimensions notably the
machine life cycle and internationalisa-
tion. Which is why Eisenmann chose
SICK for the safety automation of MTUs
articulated shaft production.
MTU Friedrichshafen GmbH:
technological leader in diesel
engines and drive systems
The company MTU Friedrichshafen
GmbH supplies diesel engines and com-
plete drive systems for ships, heavy land
and rail vehicles; industrial drives; and
decentralised energy plants. In addition
to complete aggregates, the Articulated
Shaft Product Centre at MTU annually
produces about 1 million articulated
shafts. Areas of use include cars and
light commercial vehicles. In 2006 Eisen-
Safe complete solution, programming included
Dynamic safety for articulated shaft spraying plant
Wanted: safety technology system supplier with all-round service provision
concept. This was Eisenmanns job advertisement for the safety-oriented automa-
tion of articulated shaft production at their end-customer MTU in Friedrichshafen .
The position was won by SICK with safetyPLUS
the complete solution with

sensors , control technology and services from a single source.
mann among other things, the leading
international system supplier in the ar-
eas of surface technology and material
flow automation obtained the order
from MTU to construct a spraying and
packaging plant for articulated shafts. As
a plant constructor focused on its own
core competences, Eisenmann sought
a competent system supplier to provide
support from creating a solution for the
task in hand, through planning and im-
plemention, to training and service provi-
sion for the end-customer. This complete
package, which also included wide-rang-
ing programming tasks by SICK, was vital
for the job of protecting the articulated
shaft plant and a subsequent packaging
plant which is, to some extent, manually
operated.
Dynamic protection, not a
static solution
Racks of differing dimensions are used
for loading and transport in the articulat-
ed shaft plant. The stack of racks, empty
or full, is picked up by a forklift truck.
Transport to the filling station takes place
by means of a stationary steel-plate con-
veyor system. The empty racks are filled
with articulated shafts at a manual work-
place. Depending on how high the stack
is, it is moved to a comfortable height
for the workers. The racks are moved by
means of a line gate with a gripper on
the Z-axis. Three of these structures are
set up in the plant near one another. The
fact that the gates are also moved for
use in a variety of departments necessi-
tates a dynamic adaptation of the safety
area during running operation without
loss of safety while the operating mode
is changed.
Systematic safety: sensors, control
and service from a single source
The UE4470 safety controller is at the
heart of the system solution, in addi-
tion to inductive safety sensors of the
IN4000 series, C4000 safety light cur-
tains, and M4000 multiple light beam
safety devices. The UE4470 is integrat-
ed in the PROFIBUS-DP environment
and allows appropriate sensors (such
as safety light curtains), emergency stop
buttons, or gate safety queries to be logi-
cally linked to one another via certified
functional blocks. This allows process-
oriented activation or deactivation of the
particular protective areas and systems
in the articulated shaft plant. Status,
diagnostic and fault messages are de-
tected and processed locally and via the
network during operation. The constant
testing of the connected components for
correct function takes place by means of
so-called test signals.
Safety automation of MTUs articulated shaft production with safetyPLUS
The C4000 safety light curtain is

easily integrated
Production of articulated shafts
: Applications
09
Safe complete solution, programming included
Dynamic safety for articulated shaft spraying plant
insightLINK
INFO 105
www.mtu-online.com and
www.eisenmann.com
>> The joint development between
the Bremen Institute of Industrial
Technology and Applied Work Science
(Biba), Astrium Space Transportation
and Deutsche Post World Net lasted four
years. The result was presented a few
months ago: the worlds first fully au-
tomatic package robot that can unload
containers autonomously. Among other
things, the new package robot first had
to learn to perceive and analyse its sur-
roundings in order to derive the correct
handling steps to enable automation of
the physically heavy unloading work on
the ramp.
LMS200 the eye of the robot
The LMS200 laser measurement system
provides the essential visual capabil-
ity. The laser optics, measurement unit
and evaluation electronics are accom-
modated in a compact housing. The
maximum operating range is 80 m, and
is 10 m with just 10% object reflectivity
this allows the robots control system,
developed by the EADS aerospace sub-
sidiary Astrium Space Transportation, to
navigate in the direction of the container
and detect the packages at close range.
The very fine angular resolution of 0.25
allows the reliable detection of even the
smallest of details. The LMS200 has an
adjustable angular range of between 0
and 180 so that measurement fields
of differing widths can be adjusted ac-
Perfect package detection
A robot unpacks
Robots have long been able to insert packages into a freight container. Automati-
cally taking packages out of containers has only become possible recently not
least thanks to the LMS200 laser measurement system.
cording to, for example, the size of the
freight container. With the help of the
LMS200s powerful evaluation unit the
robot can rapidly and accurately detect
the position of the individual packages
and grip them with its vacuum-supported
six-joint hand. Then the robot sets down
the package on a conveyor belt behind
it, which transports it further into the
freight or logistical centre.
Serial production in spring 2007
The trials that the automated unloading
system underwent at the Deutsche Post
Net World were so successful that the
Bremen company ThyssenKrupp Krause
has further developed it for serial produc-
tion and is now selling it worldwide under
licence. The first practical use started in
March at DHLs Logistics Centre in Essen .
Other well-known companies from Ger-
many, Italy, Finland, Denmark, the USA
and Iran have already shown interest in
purchasing it.
insightLINK
INFO 102
www.robotik-logistik.de
Planned safety is cost-
minimised safety
The wide-ranging safety technology colla-
boration with a system supplier during
the MTU project has paid off for Eisen-
mann. Thus expert knowledge could al-
ready be taken into account during the
conception, draft and project planning
of the articulated shaft plant, e.g. during
the risk analysis and the development
of a dynamic safety concept. This made
a major contribution to preventing sub-
sequent, potentially expensive, modi-
fications brought about by problems
that might have been overlooked. The
necessary safety products, including
the safety and user software, could thus
be combined and taken into account in
construction terms, resulting in a cus-
tomised and cost-optimised safety solu-
tion for MTU in its safety and automation
functions.
Summary: for Eisenmann, in safety
and system technology terms, the MTU
project not only acts as a reference, but
also as a benchmark for future projects
of this type.
The UE4470 flexible safety controller
is at the heart of the system solution
Unpacking system
P
h
o
t
o
:

B
i
b
a
: Applications
1/2007 10
>> Ostwerwalder AG is a technological
leader in the area of system solutions
for pressing iron, ceramic, or hard metal
powders and other materials. Customers
for powder presses such as the UPP 8000
are sub-contractors for the automotive
industry that use the plants to produce
drive parts and other complex products.
These customers place particular worth
on flexible use of the machines, on great
precision, and on minimising downtimes
and equipping times, says Urs Straub
in Osterwalders Electro-construction
Dept. Adjusting eight axles and more
manually within a short time and with
an accuracy of 0.01 mm is very demand-
ing with mechanical handwheels. With
HIPERDRIVE

, Osterwalder AG is using a
positioning solution that offers both ra-
pidity and precision.
Osterwalder AG relies on positioning
drive for powder presses
Goodbye manual work
The Swiss company Osterwalder AG equips its fully hydraulic powder presses with
HIPERDRIVE
positioning drives for adjusting the limit stops of axles. Time savings
combined with more precise adjustability are the most important arguments for
HIPERDRIVE
and against mechanical handwheels.

insightLINK
INFO 106
www.osterwalder.com
Absolute measurement system
with PROFIBUS connection
HIPERDRIVE
(Highly Integrated Perform-

ance Drive) is an integrated positioning
drive in which the motor, drive, absolute
measurement system, and performance
and regulatory electronics are accommo-
dated in a single compact housing. The
absolute detection of the angle of rota-
tion provides a unique positional value
for each axle position no reference run
is necessary when starting up the auto-
matic powder presses. The positioning
drive is integrated in the CNC machine
control system via a PROFIBUS-DP clip-
on module. This was also a decisive ar-
gument for using the positioning drive
because the more axles a press has, the
more the PROFIBUS connection reduces
the wiring effort, adds Urs Straub.
Rapid and precise
Up to now, the adjustment spindles have
been very difficult for machine operators
to reach because of the large dimen-
sions of the powder presses. Reaching
and precisely adjusting the axle limit
stops takes a certain amount of time,
Urs Straub remembers. It is now much
quicker with the HIPERDRIVE
position-
ing drive, because the machine opera-
tor does not need to climb onto the ma-
chine to adjust the axles manually one
after the other. He or she can now simply
position the limit stops more comfort-
ably, more quickly, and more accurately
in the 0.01 mm range at the touch of
a button.
Adjustment of the axle limit stop with
HIPERDRIVE
improves both the pow-

der presses user-friendliness and their
adjust ment and repeatability accuracy.
Above: The HIPERDRIVE
positioning drive
Left: The upper and lower sections of
UPP 8000 powder presses each have
four motor-regulated axles as standard
Powder press
: Applications
11
>> And courage is definitely required if
one is working on an automatic palletiser
whose safety monitoring has been modi-
fied by non-experts in the works.
Signals are lost
Modifications frequently result as in
a real case known to ACMI from prob-
lems during the process. Fully loaded
pallets in this case with glass bottles
and large tins correctly triggered the
muting function during entry to the pal-
letiser. But the muting sensor signals
were sometimes lost when the pallets
were only partially loaded. The conse-
quence: a machine stop, reduction in
throughput, and loss of production. It
did not take long to find the solution to
this problem the muting sensors were
simply implemented in the plant for as
long as it took for all the signals to be
restored. The safety risks involved were
Muting, not a test of courage
Palletiser safety
The palletiser producer ACMI protects its systems with the M4000 Advanced multi-
ple light beam safety device together with the UE403. They provide the ideal muting
solution and prevent mounting modifications caused by courageous employees.
not initially apparent, either to the plant
user or the employees.
Decentralised muting with
M4000 Advanced and UE403
ACMI takes its responsibilities as a ma-
chine producer seriously and reacted ap-
propriately. Protection of the palletiser was
switched to the M4000 Advanced. It was
the ideal solution for local connection of
the WL250 muting photoelectric switches
with the help of the safe UE403 switching
device and decentralised implementa-
tion of the muting function. The LED mut-
ing indicator lamp is already integrated
in the end cap of the M4000 further
reducing the wiring and mounting effort
involved. The timing and logical sequence
insightLINK
INFO 107
www.acmispa.com
sures that this process now functions
properly for pallets with any load. Thus
maximum safety is achieved because
passage of the pallets out of the palletis-
er, past the photoelectric safety switch,
triggers full activity of the safety system,
even if the muting sensors are still sup-
posed to be active. In the case of only
half-loaded pallets, the partial cutting
out of the beams of the photoelectric
safety switch compared to complete
muting ensures increased safety, be-
cause at least the uppermost beam re-
mains active .
Thanks to muting with the M4000
Advanced and UE403 it is no longer pos-
sible for palletiser safety to be compro-
mised.
Top: The M4000 multiple light beam
safety device with UE403 the perfect
muting solution
Right: The LED muting indicator lamp
(green) is already integrated in the end
cap of the M4000
of the muting sensor signals are detected
and evaluated when a pallet passes the
muting station before entry to the haz-
ardous area, preventing transport being
switched off by the protective system.
Permanent safety
The adjustable filter time on the UE403
signal inputs for the muting sensors en-
Palletiser
: Applications
1/2007 12
>> Day in, day out, the high reading reli-
ability of RFID systems ensures the de-
pendable detection and process-orient-
ed diversion off the conveyor belt of all
packages tagged for special order pick-
ing despite their metallic content.
Special order picking: yes or no?
RFID system controls SOP at fittings producer Hfele
About every four minutes, an RFID system from SICK checks whether a package
needs to be diverted for special order picking (SOP) at Hfeles central depot in
Nagold. After successful technology trials at SICKs Test Centre, the complete so-
lution was installed in collaboration with system integrator Dematic.
Hfele gateway to the
world of fittings
Hfele is a leading international com-
pany for furniture fittings, architectural
fittings, electronic locking systems, and
advice on fittings for buildings. At its
headquarters in Nagold, Hfele runs its
own central warehouse with a despatch
centre. A comprehensive range of about
50,000 types of fittings is stocked in over
100,000 storage bays, administered,
picked for orders, and despatched for
worldwide delivery at short notice. More
than 3,500 orders are processed at the
central warehouse every day. If incorrect
quantities are collected for the various
order items, a package unit must be
marked as incomplete and diverted off
the conveyor for special order picking.
RFID the right technology
During reorganisation and expansion
work RFID, in the form of the 13.56 MHz
system from SICK, was selected for this
task. The RFI341 Radio Frequency Inter-
rogator read/write device offers a high
reading speed, communication ranges
of up to 1.2 m and an integrated splitter
for the connection of two antennae. The
RFID systems ensure dependable detection, and process-oriented
diversion of the packages off the conveyor belt
Order picking
The RFI341 read/write devices high
reading accuracy, communication range
of up to 1.2 m, and antennae techno-
logy that can be modified customer-
specifically are impressive
: Applications
13
Special order picking: yes or no?
RFID system controls SOP at fittings producer Hfele
insightLINK
INFO 108
www.haefele.com
They look delicious in their black dishes the ready-to-serve meals from the
southern Swedish producer Findus. But it takes a special photoelectric proximity
switch the WT18-3 to ensure that the elk steak, salmon or tagliatelle lands in
its dish accurately.
ed to look around a bit and seek a suitable
solution on the market in order to ensure
that the rim of the dish would be reliably
detected in future.
WT18-3: detects all dish rims
Food-oriented robustness, a large detec-
tion range with reliable background sup-
pression, and dependable detection of
black surfaces only one device passed
the comprehensive sensor tests involving
the combination of these three automa-
tion ingredients: the WT18-3. This pho-
toelectric proximity switch withstood the
stresses of cleaning and, thanks to its new
type of chip technology, offered the best
detection tolerance so that we did not
need to keep making millimetre-accurate
fine adjustments. Installed 50 mm above
the conveyor system, no dish rim remains
undetected, Anders Sandblom explains
his positive response and why the WT18-3
has now become the works standard at
Findus.
www.findus.com INFO 109
For 100,000 jet black dishes per day
Solution found for Findus
ready-to-serve meals
The robust WT18-3 photoelectric proximity switch reliably detects the edge of the
dish and ensures full plates
RFID units were specially adapted for the
requirements at Hfele. ISO card trans-
ponders of type TI, that the order picker
attaches to the package in a transparent
plastic bag with a clip, are used to iden-
tify the SOP packages.
Optimised by SICK in its
RFID Test Centre
The RFID solution was configured, tested
and optimised at SICKs Test Centre. The
subsequent system at Hfele, set up by
system integrator Dematic, could there-
fore be implemented rapidly and smooth-
ly, without any surprises. The reading
station was mounted on an intermediate
platform in the central warehouse. The
approaching packages or sometimes
plastic containers with loose parts or
little material are separated by about
1.5 m. Every 3 or 4 minutes the reading
system is triggered by a new package
with an ISO transponder. When a good
read signal is detected, the RFID system
activates the pusher that diverts the SOP
package out. Thus the RFID system de-
tects the packages that need checking
from 530 packages per hour.
High stability in practical use
Thanks to the RFI341, the ISO card
transponder is read with high identifica-
tion reliability during practical operation.
The high detection rate achieved re-
mains constant even if the packages are
at an angle of 45 on the conveyor sys-
tem which may occur on the set-down
ramps of the packing places.
Summary: robust, powerful reading
devices; modified customer-specific an-
tennae technology; transponders with
the right packaging and with suitable
attachment to the object the RFID sys-
tem from SICK creates a system solution
for a variety of tasks.
>> Given the vibrations, and the several
cleaning processes per day with high-pres-
sure jets and alkaline detergents, I would
not want to be a photoelectric switch
here, Anders Sandblom, Automation En-
gineer at Findus, describes the operating
conditions for the photoelectric proximity
switches along the 1.2 km filling line. And
because we changed from white paper
dishes to black plastic ones for aesthetic
reasons, the old sensors didnt have a
chance.
On or beside the dish
the rim is decisive
Findus produces almost 100,000 ready-
to-serve meals every day. Thus space
on the conveyor system is correspond-
ingly tight: an uninterrupted flow of black
dishes passes the individual filling stations
which always have to know whether the
dish has arrived. The sensors did not al-
ways provide the correct answer and the
elk steak would miss out on its sauce, An-
ders Sandblom remembers. Findus decid-
The food industry
: Applications
1/2007 14
>> The answer is yes, the M4000 Stand-
ard multiple light beam safety device.
It is used on a variety of sheet metal
processing machines at TRUMPF, one of
the worlds leading suppliers of machine
tools for laser cutting, stamping, form-
ing and bending. Several machines can
be monitored simultaneously by a single
system with the help of deflector mir-
rors. The M4000 Standard has an inte-
grated AS-i Safety at Work interface. This
allows the photoelectric safety switch
to be integrated in the communication
structure as a safe sensor.
Modularity is TRUMPFs trump
TRUMPF relies on modular plant con-
cepts that permit expansion of the ma-
chines with differing modules right up
to complete production cells. The same
applies for the level of automation,
which is also designed customer-spe-
cifically. Therefore the safety technology
used to protect the machine or plant
must also exhibit a correspondingly high
level of flexibility in order to meet all the
demands with as few basis components
as possible. This is why TRUMPF exploits
the two-beam version of the M4000
Standard multiple light beam safety de-
vice from SICK.
Access protection around the corners
Many questions one answer
Is there a protective system with which one can protect both a single machine or
a complex production cell? Is there a solution with which one can simultaneously
monitor several sides (in effect, around the corners) with just one Category 4
safety sensor? And is there such a system with an AS-i bus?
M4000 leading safety technology
Whether Standard or Advanced (inde-
pendent of the particular functional
scope required), access protection is
the fundamental function of all M4000
devices. Single- or multi-sided access
protection is achieved with the M4000
Standard, which offers numerous fea-
tures that are not really standard: the
laser alignment aid, the configuration
buttons on the device, the LED indica-
tor lamp on the receiver housing, the
separate connection on the receiver for
direct wiring of the reset button, and the
integrated AS-i Safety at Work interface.
Of these, TRUMPF principally exploits
the following advantages on its Tru Laser
laser cutting systems and TruPunch
punching machines.
TRUMPFs trump no. 1:
the integrated alignment aid
With the assistance of deflector mirror
columns, the M4000 Standard can pro-
tect all of a machines open sides with
just a single system. The integrated
alignment aid provides simple adjust-
ment of the transmitter, mirror columns
and receiver. The consequence is rapid
commissioning, considerably reduced
servicing, and fewer machine down-
insightLINK
INFO 110
www.trumpf.com
times in brief: greater machine avail-
ability.
TRUMPFs trump no. 2: the integrated
AS-i Safety at Work interface
In communication terms, TRUMPF re-
lies on the Actuator Sensor Interface
(AS-i). As the M4000 has an integrated
AS-i Safety at Work interface it can be
connected to the yellow AS-i bus cable
by means of an M12 clip. This provides
both the M4000s power supply and
reliable signal transfer via the two-wire
cable. This offers TRUMPF a decisive
advantage: the control concept of the
entire plant is simplified and the wiring
effort reduced.
Free machine access and AS-i connec-
tion: the M4000 Standard is highly con-
vincing.
The new PM3S mirror columns
greater availability due to more
robust column profile and simpler
alignment thanks to mirror area that
is 40% larger
The M4000s integrated laser beam
considerably simplifies alignment, par-
ticularly with several mirror deflections
Protecting machine tools
: Applications
15
>> Johnson & Johnson is the worlds
largest health care company. Its prod-
ucts are sold in 175 countries and
range from successful baby and body
care brands, through hygiene products
and medicinal cosmetics, to pharma-
ceuticals, surgical wound care, im-
plants and minimum invasion instru-
ments. The Group consists of 200 com-
panies, with about 110,000 employees
in over 54 countries worldwide e.g. in
Thailand . The works here supplies sev-
eral countries in South-East Asia. For a
long time, products such as wet wipes
or talcum powder were logistically con-
trolled and tracked solely on the basis
of their bar codes. But the EAN 13 bar
codes contained no country-specific
differentiation so it was always pos-
sible that products with linguistically
differing packaging could get mixed
up, and an end-customer in, say, the
Philippines , received products destined
for Taiwan!
Country and language information
integrated in 2D code
The idea of attaching a second coun-
try bar code was quickly abandoned
for space and cost reasons. Instead
Johnson & Johnson now uses an ad-
ditional small data matrix code with a
Tracking & tracing in the medicinal field
with 2D code readers
Babylonian misunder-
standings straightened out
An end to Spanish packaging for Taiwan, Chinese labels on products destined for
Singapore the use of ICR840 2D code readers at Johnson & Johnson in Thailand
has allowed the prevention of products going to the wrong countries.
cell size of just 0.33 mm x 0.33 mm,
for which there is enough space on the
packaging and which does not adverse-
ly affect the design of the packaging or
label. It was therefore necessary to find
a suitable reading system that could
read the codes at a speed of 0.4 m/s
on a transport system while coping with
the critical packaging surface (similar
insightLINK
INFO 111 or on Page 36
www.jnj.com
to plastic), and which was also easy to
use and program.
More than a dozen production lines
equipped with ICR840s
SICK Singapore suggested the ICR840
as a solution the local integrator Plan-
et T&S inserted the 2D code reader, with
its 1.3 megapixel CMOS matrix sensor,
into a total solution with a PC, PLC and
control unit. Integrated software assist-
ants simplified Ethernet connection
and the teach-in of the codes to be de-
tected. The image repeat rate is 25 Hz
with an image field of 44 x 35 mm
2
and
a resolution of 0.2 mm. If the location of
the code on the object is known (due to
technical process conditions, for exam-
ple), the reading field can be restricted
if desired, and the image repeat rate
increased to over 100 Hz which leads
to a multiple reading of each code, and
thus to increased process reliability, as
the code is reliably detected several
times as it passes by.
After successful initial trials,
Johnson & Johnson ordered a total of
17 complete reading stations for its
production lines. Since then, there has
been no more mixing of products and
an end to the Babylonian linguistic con-
fusion.
The ICR840 stationary 2D reading device reads the country and language informa-
tion integrated in the small data matrix codes
Pharmaceuticals
1/2007 16
: Applications Production system
>> Displacement sensors with CMOS
technology, such as the OD Max, meas-
ure in the micron-range. They monitor
the presence and positions of objects,
measure profiles and diameters, regulate
processes, and take on other quality-in-
specting functions. For example, on the
engine blocks and cylinder heads of the
automotive supplier Nemak (which spe-
cialises in aluminium engine blocks), the
tasks here are to check whether the re-
moval of material at a cutting station has
taken place as defined, and whether the
surface of the engine has been damaged.
The high-precision sensor that is required
must be installed far enough away from
the robots handling area.
OD Max the maximum solution
The OD Max was chosen for a variety
of reasons. The OD350 version offers
a measurement range from 250 mm to
450 mm with an accuracy of +/ 0.2 mm.
This meets both the distance and accu-
Processing checks on aluminium engine blocks
Detailed inspections over long distances
Fanuc Robotics has implemented a fully automatic engine block testing system
at the automotive supplier Nemak in Windsor, Ontario, Canada. Installed at a safe
distance from the robot, OD Max displacement sensors very precisely detect the
processing quality of the aluminium die-casting.
racy requirements. The CMOS technology
of the OD Max measures both reflective
and rough aluminium surfaces extremely
reliably and with micron resolution. The
concept of a separate sensor and evalu-
ation with an LCD display is characterised
by the simplest possible installation, com-
missioning and operation. With four ana-
logue outputs, five switching outputs and
an RS-232 interface, the OD350 offers all
the important data output methods.
Nothing wrong with the
height difference
A Fanuc robot moves the cylinder block
to the inspection station after it has been
processed in the cutting centre. At the
inspection station, three OD350s are in-
stalled on a profile column in such a way
that they can view on the quality-relevant
locations of the die-cast surface of the
engine. Using distance measurements,
the surface of the semi-finished part is
aligned parallel to the sensor faces before
insightLINK
INFO 112
www.fanucrobotics.com and
www.nemak.com
the actual quality inspection. Then the ro-
bot moves the cylinder block linearly so
that the surface can be measured by the
displacement sensors. Calculation of the
height difference between the unproc-
essed and processed surface is based on
this measurement. Everything is in order
when the height difference lies in toler-
ance with the pre-set height difference.
The height difference to be achieved can
be between 0.25 mm and 3 mm. If it is
greater than this, the cylinder block will
require extra processing. If lower, the part
is defective.
Measurement with SICK displace-
ment sensors and Fanuc robots at
Nemak means that quality can be as-
sured on the line.
Determines whether the cylinder block requires repair in the -range:
the OD Max displacement sensor with CMOS technology
: Applications
17
>> Franke makes a comprehensive
range of coils at its works in Bad
Sckingen one of Europes largest
and most modern coil production sites.
More than 100 models are available,
made of either stainless steel or high-
quality coloured composite materials,
supplemented by professional module
elements and customised stainless steel
products. A Schuler Hydrap 630 press
has been doing its duty here for years. It
was recently brought right up to date in
safety terms.
Protection of hazardous areas,
area blanking, prevention of access
The SICK LVU safety curtains previously
used could no longer be maintained, for
economic reasons, and were replaced
by the latest safety technology. Two
C4000 Advanced, with a field height of
1,650 mm and 14 mm resolution for
hand protection, monitor the hazardous
press table from the front and the back.
One 450 mm C4000 Standard each is
connected as a guest via the expansion
sockets. With a resolution of 40 mm, they
are used on the two sides of the press to
prevent access from around the safety
field. In particular operating modes, cut
waste is transported out of the hazard-
ous area via a conveyor system during
the pressing of coil blanks. For this pur-
pose, the conveyor system monitored
by SICK safety switches is pneumati-
cally inserted into the press space from
above. During this activity, the light cur-
tains dynamically blank out the press
table. The safety function is then taken
over by another C4000 Standard on the
conveyor system itself.
The UE470 takes over the
complete safety management
With reaction times of under 10 ms, the
UE470 is the most rapid safety control-
ler of its class. It is specially designed
for the safety automation of presses and
has parameterisable application- specific
function modules. A total of fifteen
inputs , eight outputs (of which two out-
Modernised under ones own steam, certified by SICK
Sensor and control modernisation
on a coil press
The aim of modernising the Schuler Hydrap 630 press at coil producer Franke was
to achieve new safety on an existing production plant. Engineers at the company
mounted five safety light curtains and integrated them in the UE470 compact
safety controller themselves.
put pairs that can be used as safety out-
puts), two-hand functionality and double
bypass offer comprehensive function
and control possibilities. In addition ,
two safe input pairs (for electro -sensi-
tive protective equipment from SICK)
are available with an internal device in-
terface. The integrated Test Pulse and
Protective Function connection options
make the UE470 a versatile and flexible
solution for protecting machines. Four
of the UE470s five possible operat-
ing modes are used at Franke: without
blanking front and back, with blanking
front and back, with blanking front with-
out blanking back, and without blanking
front with blanking back. These cover
all the potential safety-relevant process
states.
With a solemn promise:
upgrade certified by SICK
The press underwent a safety inspection
by SICK specialists after completion of
the modernisation work. The successful
inspection was confirmed and certified
with SICKs inspection seal accred-
ited by the German Accreditation Body,
Technology (DATech).
insightLINK
INFO 113
www.franke.com
Hand protection and prevention of access from behind the press
with the C4000 safety light curtain
After more than ten months operation
the user is completely satisfied with the
new system maintenance times have
been greatly reduced and productivity
has risen accordingly.
The UE470 compact safety controller
with reaction times of less than 10 ms
Protecting presses
: Applications
1/2007 18
>> Level Control i.e. the regulation of
filling height is increasingly required in
processes related to production, packag-
ing and logistics. This is because over- or
under-deliveries rapidly impair quality
and corporate image, and can lead to
high costs if parts are missing, custom-
There is no replacement for delivery quality
not even in the spare parts store!
150,000 different articles original spare parts, tyres, accessories, and consum-
ables for Audi, Porsche, Seat, Skoda and Volkswagen are stored in the central
spare parts store of Switzerlands AMAG Automobil- und Motoren AG. There is,
how ever, no replacement for the LMS400 laser measurement system with Level
Control and the view it offers into the transport boxes.
ers obtain too many goods or when as
was the case at AMAG the circulatory
system believes that there are still goods
in what are actually empty transport box-
es. Containers that are not empty may
also cause two types of error: the goods
are not all removed from the transport
box in the Outgoing Goods Dept. or the
transport boxes with the goods enter
the circulatory system without any de-
fined destination. If returned boxes are
re-stored without inspection, such errors
remain undetected and lead to wasted
time, complaints and clarification effort
for both customers and AMAG, as well as
costs for correcting the error.
No costs thanks to 100% view
in the boxes
This task has been solved in AMAGs cen-
tral spare parts store in Buchs near Zurich
with the LMS400, integrated in the plant
by the Swiss logistics company Swisslog.
The measurement system has been in-
stalled on a frame above a segment of
the conveyor system, via which the boxes
are transported to the despatch area
at a speed of 1.2 m/s. When a box ap-
proaches, the trigger signal generated by
a photoelectric switch initiates the meas-
urement process. The floor of the box (di-
mensions: 600 mm x 400 mm x 270mm)
is scanned while passing below the frame.
insightLINK
INFO 114 or on Page 42
www.amag.ch
Whereby every object in the box, down to
a size of 50 mm x 50 mm x 20 mm, is
reliably detected. Even objects that form
a completely homogeneous surface for
example a complete layer that has not
been removed are reliably detected.
Thus AMAG ensures that only empty
boxes are stored in the empty container
stores and that consignment errors are
reliably prevented during the delivery of
about 11,000 items per day.
Assured delivery quality with style
The process, cost, and image advan-
tages gained by using the LMS400 are
available to numerous applications and
sectors, e.g. distribution centres; mail
order houses; courier, express and pack-
age service providers; breweries; dairies
or food producers.
The blue box of tricks for a view in-
to the box: the LMS400 now allows even
small objects with unfavourable detec-
tion properties to be reliably detected in
moving containers with an all-in-one
sensor.
In the AMAG central spare parts depot, every object is reliably detected in the box thanks to filling height regulation
The measurement system installed in
a gantry above a segment of the
conveyor belt
Automotive
: Applications
19
Nozzle inspections for diesel aggregates
First find, then measure
The automatic inspection of holes with diameters of 0.2 mm is already difficult
enough. It becomes a real challenge when the position of the hole varies and it
must first be found. This is where the IVC-2D smart camera comes into its own as
a clever measurement solution.
>> VMK Engineering a developer and
producer of both individual machines
and complete automated production
lines approached SICK in the Czech
Republic. The company had developed
a machine for a customer for produc-
ing valves for diesel aggregates and was
seeking a way of checking that the noz-
zle diameter of 0.2 mm was maintained
with an accuracy of +/0.02 mm. As a
result of the shape of the casting, howev-
er, the nozzle opening was not centrally
located but off-centre. This meant that
the inspection system first had to find
the nozzle in its random position before
measuring it.
The solution: camera inspection
with background light
Some other sensor solutions lost the
nozzle but not the IVC-2D. It is installed
above the test-piece which is backlit, al-
lowing measurement using a transmit-
ted light process. The camera has a
resolution of 1024 x 768 pixels. A single
image capture step allows the position
insightLINK
INFO 115
www.vmk.cz
Left: The IVC-2D smart camera checks
the nozzle diameter of 0.2 mm
Top: The correct server software was
also programmed
of the hole to be found first by scanning
its edges, and then determines whether
the diameter of the hole is within the pro-
grammed tolerance value.
From the feasibility study to
the complete solution
The first feasibility study in SICKs appli-
cation laboratory was just as success-
ful as the live trials at VMK. The display
of the inspection process with the help
of the IVC Studio visualisation program
showed that the camera could both find
the nozzles and reliably measure their
diameter. And incidentally, SICK in the
Czech Republic also programmed the ap-
propriate server software after a request
from VMK, and supported integration of
the complete solution in the machine.
VMK, however, is not only very sat-
isfied with the support it receives from
SICK, but also with the IVC-2D itself: it
has so far exhibited over 99.8% reliabil-
ity during more than 10,000 measure-
ments.
Machine tools
1/2007 20
>> The LiftMaster series from Trumpf
Sachsen GmbH in Neukirch is a pivoting
system for the automatic handling of un-
treated sheet metal, sheet metal blanks
and grids on flatbed laser cutting ma-
chines. The LiftMaster, available in four
sizes, has a basic design that consists
of a suction frame vertically mounted
on a lifting column. The sheet metal to
be used is first picked up by the vacuum
suction system from a stack of untreated
sheets. Then so-called transport catch-
ers close below the raised sheet so that
the sheet lies upon them during the piv-
oting movement and the vacuum supply
can be switched off. During the putting-
down process, the LiftMaster suction
frame takes over the sheet again, the
catchers open, and the sheet is laid on
the machine pallet.
Photoelectric switch manages automatic
sheet metal handling
Trumpfs trumps
Whether for detecting limit stops, individual sheets of metal, and storage slats on
machine pallets, or determining the height of a stack of sheet metal the compa-
ny Trumpf Sachsen GmbH consistently relies on the WS/WE18-3 through-beam
photoelectric switch for automation of its flatbed laser cutting machines.
Pick-up and set-down
with the WS/WE18-3
Trumpf Sachsen solves all the detection
tasks with the WS/WE18-3 through-
beam photoelectric switch. Three WS/
WE 18-3 units are used on each suction
frame one longitudinally on one side
of the sheet metal, and two transversely
above the format diagonals. They are
installed in a protective housing on the
frame to protect them from damage or
insightLINK
INFO 109
www.de-neukirch.trumpf.com
unintentional readjustment. Before a
metal sheet is picked up there is a check
to ensure that no positioning limit stops
are still present on the storage wagon
upon which the stack of unprocessed
metal sheets sit. Then it is necessary to
ensure that only one individual sheet is
raised and that it is lifted in its entire-
ty. The machine pallets set-down slats
must be detected before the catchers
open when the sheet is to be set down.
The flatbed laser cutting machine with pivoting LiftMaster system
During placing of the cut sheets on the
finished parts stack, the WS/WE18-3
units determine the height of the stack
so that the suction frame can be lowered
to the right level.
These photoelectric
switches are trumps
The WS/WE18-3s immunity to vibra-
tions, its long range, and its reliable
function even if contaminated by parti-
cles stemming from the cutting process
proved decisive arguments for Trumpf
Sachsen. Thus these photoelectric
switches are Trumpfs trumps for auto-
mation of the LiftMaster.
: Applications Flatbed laser cutting machine
From left to right: Martin Sittig, Roland
Hackenjos (both from SICK) and Matthias
Her from Trumpf Sachsen GmbH
The WS/WE18-3 through-beam photo-
electric switch in its protective housing
on the suction frame
: Applications
21
>> Since its founding, Proxaut in Mode-
na has been one of Italys technological
leaders the country which produces
the most automated guided vehicles.
Whether ProxCAR, ProxMAG or Prox NAVY
all vehicle series offer flexible auto-
mated guided solutions. Their list of ref-
erences includes the food giant Nestl,
the glass producer Saint Gobain, and
other companies in the paper, ceram-
ics or plastics industry demonstrating
their wide-ranging field of activity.
S3000 is the safety standard
In terms of safety, the S3000 Profes-
sional is our standard solution, says Ste-
SICK: safety and navigation via laser
Flexible sensors for flexible solutions
Different sectors often require differing intralogistical transport solutions.
The Italian AGV producer Proxaut can offer this flexibility not least through the
use of S3000 safety laser scanners and NAV200 navigation systems.
insightLINK
INFO 116
www.proxaut.com
fano Ballotti from Proxaut. With its shaft
encoder input and switchable path- and
speed-dependent protective and warn-
ing fields, the scanner offers decisive
prerequisites for mobile use.
The most flexible navigation solution
He sees the NAV200 navigation system
as the ideal supplement, whenever re-
quired, because it allows considerably
more flexible adaptation to the path
layout and conditions in the hall than,
for example, wire-guided systems. The
NAV200 offers an accuracy of < 5 mm
and thus enables vehicles to stay on
the drive paths while achieving highly
accurate docking processes, confirms
Stefano Ballotti. Like optical radar, the
NAV200 detects reflectors mounted in
the area at distances of up to 30 m and
through 360. Combination of the angle
and distance provides accurate determi-
nation of the vehicles position and align-
ment.
S3000 and NAV200 the perfect duo
from SICK for flexible AGV solutions.
Left: Stefano Ballotti from Proxaut
in front of an AGV equipped with the
NAV200 and S3000 Professional
Automated guided vehicles
: Applications
1/2007 22
>> Reflective surfaces, omnidirectional
reflections, difficult contrast relation-
ships what only allows middling read-
ing results with the complicated mam-
moth image processing system used at
another location is no problem at all for
the compact IVC-2D.
Reading numbers and characters at Ford
2D smart camera detects CARIN best
Theres a fiesta mood at Fords Fiesta
body shop: a solution has finally been
found for reliably reading the CARIN
(CAR Identification No.) with the
IVC-2D smart camera.
Car body identification:
focused on CARIN
CARIN plates with a sequence of 7 num-
bers and letters are used to identify car
bodies at the Fiesta B-Car body shop at
Fords works in Cologne. The plates are
etched on two machines, manually in-
serted in a riveting tool (depending on pro-
duction frequency), and riveted onto the
front partition panel in the engine com-
partment. It was necessary to find a solu-
tion for reading the CARIN plates in order
to rule out any mix-ups and the corre-
insightLINK
INFO 115
www.ford.com
sponding extra effort this would involve in
the final acceptance line before transfer to
the spray shop. Fords essential demands
were: a compact sensor housing for instal-
lation on a pneumatic pivoting arm, high
reading reliability in difficult conditions,
integration in Fords ILVS (In-Line Vehicle
Scheduling) system, and visualisation of
the CARIN codes on a monitor.
Better reading with the IVC-2D
Positive experiences with SICKs smart
cameras in other Ford assembly areas
led to the idea of also using the IVC-2D for
this task. The first trial runs in the Body
Shop Servicing Electronics Workshop
showed that the camera was capable of
far exceeding Fords demands. Use of the
ICL80 green-light illumination unit led to
very good contrast relationships diffi-
culties caused by the strongly reflective
surface of the aluminium CARIN plates
and the omnidirectional reflections within
the etching itself were completely elimi-
nated. Programming with IVC Studio (for
reading of the OCR characters, setting up
filter functions for optimum contrast, and
other parameterisation) proved easy and
was carried out by Ford personnel. Inte-
gration in the ILVS system was achieved
without any trouble, as was visualisation
of the CARIN data on a monitor (via the
web server integrated in the camera).
Each expected number, detected number
and live picture is displayed on the screen
during this 100% inspection.
Collaboration to continue
The possibility of car body confusion
resulting from CARIN reading errors has
been completely eliminated by introduc-
ing the IVC-2D. Which is why Ford intends
to continue its relationship with the
IVC-2D. As a result of the positive ex-
perience at the CARIN plant, a second
system will be ordered in early 2007 and
installed in the transfer station to the
Paint Shop to replace the complicated
system currently used there.
The CAR Identification Number (CARIN) can be reliably read by the
IVC-2D compact 2D smart camera
Automotive
: Applications
23
>> Product protection and pallet load
safety are the main functions of Haloilas
stretch-wrapping machines. Two rolls of
foil provide simultaneous wrapping at a
tremendous speed. Two factors mean
that the machine requires protection
against unauthorised access or open-
ing: transport to and from the machine
takes place via automated conveyor
technology, and the rolls require regu-
lar changing. Entry of the pallets to, and
their departure from, the stretch-wrap-
ping machine are each monitored by one
M4000 multiple light beam safety device
with muting. A safety magnetic release
system controls the access gate.
Tangled linkages
All these sensors, as well as the emer-
gency stop button, require control and
monitoring. Up to now, a total of six
safety relays have been responsible for
this four for the M4000 and one each
for the magnetic release switch and
the emergency stop button. They were
wired up to one another in a compli-
cated manner to create safe logic func-
tions. The tangled linkages had little
to offer in terms of rapidity or flexibility
characteristics for which the stretch-
75% less space required in the control cabinet, only two instead of six switching
modules, considerably reduced wiring, but full functionality and safety the soft-
ware-free UE410 Flexi safety controller is exactly what the Finnish stretch-wrap-
ping machine producer Haloila was waiting for.
wrapping machines from Haloila are
famous.
Control now as transparent
as the foil itself
Its clear Haloila wanted to get rid of
any possible tangles and has now found
the right solution with the software-free
UE410 Flexi safety controller. Based on a
main unit, almost any desired number of
input, output and fieldbus modules can
be added. This is flexibility. Any control
solution can be displayed and checked
in advance with the Flexi configurator
(see Page 44). This is rapid and cuts the
engineering effort involved. Two mod-
ules, with a total housing width of 45 mm
(instead of the former 225 mm) are suffi-
cient for implementing the safe function-
al logic for a stretch-wrapping machine.
This saves space on the mounting rail.
The individual modules communicate
with one another via a data bus and their
functions are selected by means of a ro-
tary switch both features that almost
entirely eliminate wiring effort.
Less is more with the UE410 Flexi and
this is not only good for Haloila.
www.haloila.com INFO 117
Less space required,
less wiring effort
Safe automation:
less is more
No tangled foil thanks to the software-free
UE410 Flexi safety controller
Wagons checked by
laser measurement
Empty spaces
>> Before the loading of iron ore can take
place in the mines of Companhia Vale
do Rio Doce in the Brazilian state of Min-
has Gerais, LMS211 laser measurement
systems check whether the wagons really
are empty or whether other materials, or
even persons, are within them.
The solution was worked out by au-
tomation engineers from CVRD, the local
SICK distributor. The Companhia de Vale
do Rio Doce required a solution that
ensured that empty wagons were still
empty after their return from the seaport
of Tubarao, and that any unexpected
contents (or people in the wagons) were
reliably discovered before reloading.
The view from above informs
An outdoor version, high measurement
accuracy even on dark surfaces, largely
immune to ambient conditions, and ex-
perience gained from numerous similar
applications were the most important
reasons for selecting the LMS211 laser
measurement system. Mounted on a gan-
try above the rails, it looks into the empty
wagons from above and reliably detects
whether other materials are inside. The
LMS211 issues an alarm as soon as it
detects something that does not belong in
the wagon, and activates a camera which
takes a closer look and transfers the pic-
tures to the control room.
The Companhia de Vale do Rio Doce
is a perfect example of the detection
of empty spaces: a total of 14 of these
space-reporting gantries are in use. This
is fine for the CVRD automation office
throughout Brazil they are now consid-
ered the specialists for such cases, as
well as other laser and volume measure-
ment applications.
www.cvrd.com.br INFO 102
: Applications
1/2007 24
All-round view and cycle start: a compact safety
solution for circular grinding machines
Vertical protection of
hazardous point-of-operation
The Swiss machine producer TSCHUDIN relies on the S300 compact safety laser
scanner to protect its centreless circular grinding machines. This offers effective
protection for machine operators during the process of loading production parts
and is also used for automatic cycle starts.
insightLINK
INFO 118
www.tschudin.info
>> The centreless circular grinding ma-
chines from TSCHUDIN in Grenchen offer
highly accurate processing of cylindrical
parts with one or more diameters. Dur-
ing the loading of such parts into the
machine, the so-called rest moves out of
the grinding area on a sliding carriage.
This creates a hazardous point-of-opera-
tion for the operator between the safety
hood and the sliding carriage which
must be protected.
Small eye with a large field of view
The hazardous area on the circular grind-
ing machine used to be protected with a
light curtain. But it turned out that the
mechanical mounting of the light curtain
on the machine was awkward for the op-
erator, explains Urs Tschudin, Managing
Director of TSCHUDIN. We were looking
for another solution because the operat-
ing area was also too restricted as a re-
sult. The latest generation S300 safety
laser scanner represented a convincing
solution for this application. With its 8-
metre warning field radius and 2-metre
protective field radius, as well as its
270 field of view, the compact device
is a reasonably priced solution for this
hazardous point-of-operation and guar-
antees effective protection for operators.
The S300 Standard is mounted level with
the electrics cabinet on the machine and
monitors the hazardous point-of-opera-
tion vertically. The device scans the area
between the safety hood and the sliding
carriage within a programmed range of
45. Driving the sliding carriage out with
the rest for loading of the production
part interrupts the protective field of the
safety laser scanner, and the grinding
process is immediately stopped.
Start the machine cycle autonomously
Up to now it has been necessary for the
operator to press the start button to re-
start each grinding process manually.
This could be as often as 200 times per
hour and was unacceptable for both eco-
nomic and ergonomic reasons. The S300
Standard has taken over this cycle start.
Now, when the sliding carriage moves
back again, the warning and protective
fields of the S300 are reactivated and
the machine restarts the grinding proc-
ess automatically.
Space-saver in a range
of functional variants
The S300 series offers excellent safety
features in an unparalleled small hous-
ing. Certified as Type 3 according to
IEC 61496-3 and SIL2 in compliance
with IEC 61508, all the devices meet the
latest safety standards. Depending on
the variant Standard, Advanced or Pro-
fessional with one, two or four monitored
areas the S300 is suitable for a variety
of applications: instead of using safety
mats (which are subject to friction), the
S300 is ideal for space-saving preven-
tion of access from behind, for monitor-
ing insertion stations on machines, or as
protective equipment for mobile trans-
port systems or service robots.
Effective protection for the machine operator during the loading
of production parts the S300 with a 270 view
Circular grinding machines
: Applications
25
>> The system, developed by Research
Manager Marco Lucisano and his col-
leagues, measures how strongly a pa-
perboard sample deviates from a flat
surface, i.e. the curl and twist of the
sheet. These characteristics are impor-
tant control values for the papermaker
when selling paperboard to the packag-
ing industry, he says. Any excessive
Packaging paper: curl and twist as a measure of quality
Camera solution packed
with information
The STFI-Packforsk research institute in Stockholm has developed an optical
measuring system to determine the quality of packaging paper. The IVC-3D smart
camera is the heart of this powerful system solution.
insightLINK
INFO 119
www.stfi-packforsk.se
distortion can cause problems during
the further processing to create the fin-
ished packaging.
IVC-3D: output of measured
values via web-server
The measurement system consists of
three sub-units: a moistening unit (with
which the various degrees of humidity of
Research Manager Marco Lucisano together with the optical measurement
equipment which determines the quality of packaging paper
the paper sample can be simulated); a dri-
er (which thoroughly dries the paper using
an infrared beam); and the IVC-3D smart
camera from SICK IVP. We selected the
camera with the help of Staffan Hakans-
son from Mabema Consulting, explains
Marco Lucisano. They are real image-
processing experts who specialise in au-
tomatic optical inspections for Swedens
processing industry and have the relevant
3D camera competence.
The samples are 10 x 10 cm
2
squares
that are laid out on a rotary table. On rota-
tion, they pass below the infrared drier and
the IVC-3D smart camera. This measures
how much the samples deform under dif-
fering humidity conditions. If the paper-
board is moistened or dried it takes on a
cylindrical form and we can use the cam-
era to directly measure the interior radius,
i.e. the twist and curl, in the form of x- and
y-coordinates, explains Marco Lucisano.
As the camera has a built-in web-server
with its own IP address, we can transfer
the measured values directly to a PC, on
which a finished image composed from
the measurement points then appears.
Live tests at users
A variety of paper producers participated
in the research project. Some of them will
now comprehensively test the inspection
system. If it proves effective, it will pro-
vide considerably more rapid and precise
measurement results than systems hith-
erto used for quality assurance.
The packaging industry
>> Further reading
Further information on the new
3D smart cameras can be found
on Page 54
: Applications
1/2007 26
>> With an annual production capac-
ity of 800 new systems and 16,000 lift
maintenance contracts, OSMA-Aufzge
Albert Schenk GmbH & Co. KG in Osna-
brck is one of the leading producers
of personal and panorama lifts, as well
as lift systems for beds, cars or loads
of almost any type. Whether blocks of
flats, office buildings, nursing and senior
citizens homes, department stores or
industrial plants it is important to stop
cabins level with the floor. Why? There is
a danger of tripping up whenever cabins
and floors are uneven. This risk must be
reliably ruled out when lifts are used by
Precision all the way to the belle tage
Lifts positioned at floor level
No steps, nothing to trip over DKS40
incremental encoders ensure that the
cabins from lift producer OSMA stop
level with the floor.
older people, or those whose movement
is limited. Moreover, in the case of goods
lifts, imprecise positioning of the cabin
during entry and exit, or loading and un-
loading, can lead to the risk of tripping
up or loads falling.
DKS40 prevents level differences
The DKS40 incremental encoder allows
OSMA control systems to stop the cabins
exactly in line with the floor. The resolu-
tion currently chosen by OSMA is 100
pulses per rotation. This corresponds
to a resolution of about 3 pulses/mm. If
the demands rise, any line number from
1 to 2,048 pulses can be programmed
as standard. OSMA emphasises a variety
of advantages offered by this encoder.
In construction terms, the space-saving
zinc die-cast devices fit perfectly onto the
insightLINK
INFO 120
www.osma-aufzuege.de
separate mounting unit of the lift cabin.
With a diameter of 50 mm and a hous-
ing height of 42 mm, the encoder is so
small and compact that it can no longer
be misused as a foot up by third-party
maintenance personnel. The connection
cable is positioned in such a way that it
can be laid without bending, and thus
protected, in a radial or axial direction.
Also ideal for maintenance
and upgrading
The compact housing, the high functional
reliability proven during testing by OSMA,
and the unusual quality considering its
application and price segment, are just
as convincing for the constructors of
new systems as for service technicians
involved in maintenance and modernisa-
tion. The DKS40 can be rapidly and eas-
ily exchanged if the worst comes to the
worst.
Lifts are basically designed to go up
and down the positioning accuracy of
the DSK40 ensures that the quality of
their movement can only go up!
Lift technology
Klaus Hebbeler from OSMA (left) with
Volker Neuenhaus from SICK in a lift
The DKS40 incremental encoder
ensures that cabins stop level with
the floor
: Applications
27
>> Engines for aviation drives, and in-
dustrial turbines and their components,
are high-tech products. MTU Friedrichs-
hafen GmbH relies on powerful tech-
nologies and processes for production.
One example is the new spraying and
packaging plant for articulated shafts.
For capacity reasons, the former manual
labelling process has now been replaced
by an innovative thermo-transfer print
station with an integrated handling sys-
tem from the company SES-Strass-
burg-Etikettier-Service GmbH in Buch-
holz near Hamburg. The CLV bar code
scanners make a significant contribution
to the consistent use and reliability of
the process data.
Double-checked on the move
The articulated shafts are between
1,000 mm and 3,000 mm long. Two
articulated shafts can be labelled si-
multaneously in the tandem labelling
station while in motion. The printing sys-
tem reads out the data from the server
database via Ethernet. Then the labels,
Identification of articulated shafts at MTU
Online label inspection
with PROFIBUS connection
Traversing CLV431 bar code scanners at variable heights check automatically at-
tached labels in the SES tandem labelling station for articulated shafts at MTU in
Friedrichshafen. The read results are reported to the plant control system in real
time via PROFIBUS.
with text and a bar code, are generated
online and glued onto the shaft by a
2-axle handling system that moves along
the shaft itself. After labelling, a CLV431
oscillating mirror scanner checks the
printing of the bar code and transfers
the reading result back to the PLC of the
SES labelling station via PROFIBUS. If
the labels content or print quality leads
to the output of an error message the
articulated shaft in question is automati-
cally diverted out for manual corrective
labelling. This route change takes place
via PROFIBUS communication with the
PLC of the conveyor system.
CLV scanners offer flexible
fieldbus possibilities
Two CLV431 units, each with a CDM420
connection module with a foil keyboard
plus display and integrated scanner pow-
er supply, are used because a tandem
plant is involved. For this application, a
CMF400 PROFIBUS Gateway is plugged
into each module, allowing communica-
tion with the labelling systems PLC. This
connection philosophy allows the use
of standard scanners, regardless of the
particular fieldbus present, so that there
is no need to purchase and stock any
fieldbus-specific scanner types.
Parameter memory
safeguards scanner settings
An external CMC400 parameter memory
module is also integrated in each con-
nection module. It contains all the scan-
ners settings data so that if the worst
comes to the worst the device can be
exchanged very rapidly and without any
loss of data or need for additional pa-
rameterisation effort. The write-protect
switch prevents any unintentional over-
writing of the parameters.
SICK scanner solutions therefore
guarantee process reliability in every
case thanks to PROFIBUS connection
and parameter storage.
insightLINK
INFO 121
www.mtu-online.com and
www.ses-strassburg.de
After checking the printing of the
bar code, the CLV431 transfers the
read result to the PLC via PROFIBUS
Labelling system
: Applications
1/2007 28
Distance sensors control production of laminated beams
First measure, then press
Austrias Springer machine factory has developed a completely new press system
the Newton 1400 beam laminating press. But before the finished laminated
beams can be produced from the lamellae, DS60 distance sensors control the fully
automatic adjustment of the press shaft which may be up to 26 m long.
>> Laminated beams, the end-product
of the pressing process, are used for
building timber roof constructions. They
provide the comfortable look and feel
of wood, but are more robust than tim-
ber beams, can carry considerably more
weight and, above all, do not distort.
The Springer machine factory
Europes largest supplier of products
for saw mill technology and the further
processing of timber has, with the
Newton 1400, now developed a new
press process. The main advantage: the
press time has been reduced to about
one hour per laminated beam. In addi-
tion, the machine offers flexible use and
is fully automated including application
of glue to the lamellae, their transport,
and the filling of the press shaft. The
DS60 is by far the best solution here,
>> Hoisting walls are installations for
lifting and lowering stage sets. For dec-
ades, the heavy scenes were moved up
and down manually. About eight years
ago Stakebrand the market leader for
theatre technology in the Netherlands
and Belgium developed the first auto-
matic control system. The latest version,
Stalogic Centurion, allows parts of the
scenery to be moved at a rate of 1.8 m/s.
Movements compared
Very complex movement patterns can be
programmed into the Stalogic Centurion
system for each use, and implemented
with great precision. This is possible be-
cause each hoisting winch is equipped
with two ATM60 encoders with SSI inter-
faces. These rotative measurement sys-
tems use a sensor to scan permanent
magnetic elements on magnetic refer-
Automatic position detection for stage sets
When the scene-shifters shift
The Dutch stage technology specialist Stakebrand B.V. uses ATM60 series
encoders to monitor the drives of hoisting winches. This provides precise
positioning of automatic theatre hoisting walls and safety-oriented monitoring
of the stage sets.
ence marks. The ATM60 offers high pre-
cision as a result of its large basic reso-
lution of 8,192 steps per rotation. The
encoders multiturn property is achieved
through several step-down gears with
magnets mounted on them. The ATM60s
absolute position signals are transmitted
to the Stalogic Centurions controller via
the encoders SSI interface.
The first encoder is located behind,
on the hoisting winchs electric mo-
tor; the second above, on the hoisting
winch itself. The two output signals are
constantly compared with one another
via a safety module. If the module finds
any discrepancies this means that some-
thing is amiss. In this case there is a risk
of injury for persons located beneath the
hanging set part the movement of the
scenery is immediately stopped. Among
other things, this technology has allowed
says engineer Franz Ebner, Springers
Construction Manager. Without the dis-
tance sensors, implementation would
be impossible or could only be achieved
with massive hydraulic effort.
DS60 ensures perfect press results
The DS60 from SICK is responsible for the
correct press result. A total of 24 distance
sensors are used in a 26 m press shaft.
They position the press cylinders or the
pressure clamps depending on the thick-
ness and length of the lamellae from which
the laminated beams are to be made. On
the basis of a reflected light beam that is
converted to a proportional electrical sig-
nal, the DS60 units determine distances
in the press shaft, i.e. its filling in terms of
width and height. These measured values
are used to stack the lamellae. Then the
hydraulic press cylinders are positioned at
a height between 0 and 1,400 mm. The
particular lamellae width (88 310 mm)
is set in the same way by means of the
lateral pressure bars. A press shaft can be
DS60 distance sensors determine
filling in terms of width and height
ATM60 encoders
reliably monitor the
hoisting drives
: Applications
29
Automatic position detection for stage sets
When the scene-shifters shift
>> The import centre supplies goods to
more than 100 distribution destinations.
7,200 packages per hour pass through
the sorter at peak times. There is thus no
time for no-reads or other reading prob-
lems maximum reliability and availabil-
ity are vital here. Which is why we de-
cided on the OPS290 omniportal read-
ing system from SICK, says Emmanuel
Perez from Cinetic Transitique.
Two-fold omni-reading
The OPS290 has become standard in
many goods distribution centres as
at Cedilec. Powerful bar code scanners
with autofocus are arranged on a gantry
frame in such a way that their reading
lines reliably detect bar codes, regard-
less of the width of the transport belt
or the size and orientation of the object
this is omni-reading number one.
The packages are also simultaneously
scanned from the front, the back, above
and below omni-reading number two.
Multi-sided reading with the help of mir-
rors (as implemented at Cedilec) is very
useful, particularly for plants in which
space is limited, says Emmanuel Perez.
This makes the OPS290 about 50 cm
narrower which is often decisive. Fur-
ther advantages, which neither Cinetic
Transitique (as the integrator) nor end-
customers would want to miss out on, in-
clude the simple diagnosis and mainte-
Package distribution for over 100 destinations
Omni-identification for
high-speed sorters
The company Cedilec in Le Havre is the main importer for the French trading chain
E. Leclerc. The order distribution system implemented by system integrator Ci-
netic Transitique has a high-performance sorter. OPS290 series omnidirectional
portal reading systems tell the sorters controller which package is destined for
which destination.
filled and closed in about three minutes,
depending on the length and thickness of
the lamellae. The press time is about one
hour, depending on the glue, at a pressing
pressure of max. 1.2 N/mm
2
. The press is
emptied in a longitudinal direction immedi-
ately after the pressing time has elapsed,
and can be filled again straight away.
Schwrer Haus KG swears
by the Newton 1400
The brilliance of this timber laminating
press concept is shown by customer
satisfaction at the housing specialists
Schwrer Haus KG in Oberstetten: The
Newton 1400 press was a decisive rea-
son for giving Springer the order, be-
cause in the longer term it offers crucial
advantages in the performance and flex-
ibility of new laminated timber produc-
tion. Anton Bohner, Director of Schw-
rer Haus KG, explains why the company
made this new investment.
In the meantime, a second machine
of the same type has gone into production
in Upper Austria. Here, too, it is the DS60
that is by far the best device for monitor-
ing the filling of the press shaft. INFO 122
www.springer-maschinenfabrik.at
www.schwoerer.de
us to apply for SIL3 certification. This is
the highest possible safety certificate for
such equipment. We are the first Dutch
producer who can offer this safety, ex-
plains the engineer and co-ordinator of
the Controls Department at Stakebrand.
SEW motors already
equipped with encoders
Stakebrand obtains the hoisting winch
motors from SEW, who already equip the
motors with the encoder in the works
and supply the units ready for use.
Stakebrand produces a total of several
hundred hoisting winches each year.
They are used in new buildings as well as
for modernising theatres, opera houses
and cultural centres. Projects are cur-
rently underway in, among other places,
Eindhoven, Almelo and Enschede.
www.stakebrand.nl INFO 123
nance of the gates and their particularly
high availability. Even if a scanner were
to fail, it would not have any significant
effect on the performance of the gate,
explains Emmanuel Perez. Thanks to
mechanical adjustment elements, and
the storage of parameter data in the
OPS control system, a scanner can also
be replaced very quickly.
The OPS290 is not, however, only
to be found at the sorter, but also in the
incoming goods area. Here it checks the
legibility of the labels on the incoming
goods and pallets ensuring smooth
passage of the packages through the
import centre. INFO 124
www.cinetic-industries.com
Smooth throughput of packages with
the OPS290 omniportal reading system
ATM60 encoders
reliably monitor the
hoisting drives
Sorting plants
: Applications
1/2007 30
>> Rolls used to be changed at a par-
ticular time during processing: replace-
ment took place so early that there was
no possibility of transport of the car body
being interrupted due to a lack of tape.
This security meant that considerably
less tape was used per roll than was pos-
sible. Which is why a sensor was sought
that could precisely detect when the ro-
bot had rolled out the last layer of tape.
After a variety of attempts the CS8 was
found to be the suitable solution: the
color sensor made it possible to reliably
detect the last layer when the white roll
body appeared during unrolling.
With its scanning distance of 60 mm
it could be directly integrated in the dis-
Checking end of rolls of adhesive tape
Color sensors hit the tape running
The adhesive tape robots in the DaimlerChryslers paint shop in Rastatt are economi-
cal in consumption and reliable in use. With the help of CS8 color sensors they detect
exactly when the yellow band is starting to run out optimising material use.
penser head on the robot at an opti-
mum distance to the roll of tape. The yel-
low colour of the tape, the white of the
roll body, and the sensitivity and detec-
tion tolerance are taught-in via a button
on the device. The CS8 sends a signal to
the controller as soon as the white roll
body has been detected for a just-in-
time roll change.
Roll-checking: economical
and environmentally friendly
Even if the tape only costs a few cents
per metre, the investment in the CS8
paid for itself within a few months. Even
with only 5% better utilisation of tape
per roll this amounts to a considerable
insightLINK
INFO 125
www.werk-rastatt.daimlerchrysler.com
savings potential. And the environment
profits too, because less unused ma-
terial must be disposed of.
A lot saved with little effort thanks to
the CS8.
The CS8 color sensor is directly integrated in the dispenser head on the robot, allowing just-in-time roll changes
Automotive
: Applications
31
>> Its all happening in the Control
House, as the high-bay warehouse for
bodies in Hall 30 is known internally.
About 600 bodies for T5 transport and
leisure vehicles are stored here at any
time. The stackers in two of the four
aisles were completely modernised in
2006. Thus the vehicles received new
three-phase asynchronous motors of
type SEW DT/DV for the chassis frame
and hoisting gear and two new, highly
precise, DME5000 laser distance meas-
urement systems each. What is special
about the device is that it is equipped
with a HIPERFACE
interface instead
of SSI.
2 x HIPERFACE
saves money and frees

up converter slots
An SEW converter of type MOVIDRIVE
MDX61B is integrated in each of the
stackers on-board control systems. The
DEH11B interface cards slotted in here
have two HIPERFACE
interfaces one
for the motor feedback system on the
drive. The second HIPERFACE
interface
remains unused in the case of position
detection systems with SSI interfaces
so that a slot must be sacrificed in
the converter for a corresponding option
Use interfaces that are available and save on, or sensibly exploit, slot-in converter
cards this is the approach taken by Volkswagen Commercial Vehicles in Hano-
ver during modernisation of the high-bay stackers in its high-bay warehouse for
vehicle bodies. SICK presents the HIPERFACE
double solution.
card/DIP11B. Not so when the DME5000
with HIPERFACE

interface is used.
Position signals via HIPERFACE

direct to path encoder input
The stackers were equipped with the dou-
ble HIPERFACE
solution after appropriate

firmware and software adaptations, and
system tests at Volkswagen Commercial
Vehicles in Hanover. Both the encoder on
the drive and the aisle positioning system
now read-in their information to the con-
verter via the HIPERFACE
plug-in card.
Firstly, this saves the cost of the SSI plug-
in cards previously required. In addition,
the reduction in hardware components
means reduced risk of failure. Finally, the
available slots in the converters can still
be used, e.g. for achieving synchronous
running functions in master/slave opera-
tion or for safe switching off via the sepa-
rately evaluated characteristic curve of an
additional encoder.
Suspicion of hype in solution for mod-
ernised and new stackers
The double HIPERFACE

connection of
motor feedback system and positioning
system at Volkswagen in Hanover has
been completely trouble-free since com-
insightLINK
on the Internet at:
www.volkswagen.com and www.vwn.de
missioning. The other two stackers in the
Control House will be updated with HIPER-
FACE
in summer 2007. This HIPERFACE

solution, however, is not just being hyped
for modernisation, but also for the new
construction of high-bay stackers as
has been shown by the numerous enquir-
ies already received.
Integrated converter solution for drive control and vehicle positioning
HIPERFACE
-hype
in high-bay warehouse
Andreas Freise from Volkswagen Com-
mercial Vehicles and Volker Neuenhaus
from SICK in the high-bay warehouse
Automotive
1/2007 32
>> The new radar device was specially
designed for bulk materials and works
with extremely short microwave pulses
with low transmitting power. The waves
are beamed by an antenna system to-
wards the bulk material surface and
then reflected. The time between send-
ing and receiving the radar signals pro-
vides exact information as to the fill level
in the container.
The MaihakPULS400 therefore not
only provides exact measured values
but is also not influenced by interfering
factors typical for bulk materials such
as dust creation or vibrations in the con-
tainer. High pressures and temperatures
also present no problems. A connected
purge air unit can also serve to provide
a clear view when required or even to
cool the antenna. State-of-the-art micro-
processor technology reliably filters out
secondary reflections caused for exam-
New highlight for continuous measurement of bulk materials:
A radar for all cases
Bulk materials play an important role in all industrial sectors. In order to meet the
demand to achieve a high level of automation in bulk material delivery, not only
the limit levels but also the actual fill levels in silos or storage containers are now
measured more often. SICK MAIHAK provides all the products required for both
tasks from one source. The highlight is the new MaihakPULS400 radar for continu-
ous and contact-free measurement.
ple by struts or container walls. Equipped
with swiveling parabolic or horn anten-
nas, the MaihakPULS400 can be used
for different repose angles and in silos
up to a height of 70 meters.
: S P E C I A L
:

S
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C
I
A
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MaihakPULS400 with parabolic and horn antenna
www.sick-maihak.de
33
: S P E C I A L
:

S
P
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C
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A large product portfolio covering measuring technique for bulk materials:
MaihakLOT369, MaihakMBA200, BULKSCAN
>> SICK MAIHAK offers one-source solu-
tions for all requirements and individual
applications in bulk level measurement.
MaihakLOT369 also for
sediments and levels
As a semi-continuous alternative for the
measurement of bulk materials with
the MaihakPULS400, SICK MAIHAK
also offers the MaihakLOT369. It can
even measure sediments in liquids, for
example for salt production. Using a float
weight, the MaihakLOT369 can also per-
manently register the level of a liquid. It
is often useful for unfavorable container
designs for example, thick concrete
walls in which only a small inlet for the
cable needs to be drilled.
The classic perpendicular measur-
ing principle is supplemented by mod-
ern electronics: in adjustable intervals,
a sensing weight is lowered on a steel
cable to the surface of the bulk material
and the fill level thus regularly meas-
ured. The MaihakLOT369 reacts imme-
diately to trapped sensing weights with
an intelligent release routine. Various
sensing weights allow use of the Maihak-
LOT369 in all branches of the industry
from spider sensing weights for typical
pyramid peaks in bulk materials to con-
tinuously measuring floats swimming on
the material.
MBA200: Limit reporting
with the proven rotating paddle
The most important measuring task in
bulk material processing remains the
early full, empty or demand level detec-
tion. Generally, robustness and reliabil-
ity are more important than inch-perfect
measurement. In this sector, the modern
rotating paddle measuring equipment of
the MBA200 series from SICK MAIHAK
is becoming more and more widespread.
It also operates according to a classical
principle proven a million times, sup-
plemented by electronic evaluation plus
self-control or warning function. The ex-
cellent materials used also make the
MaihakMBA200 suitable for extreme
applications such as in the cement in-
dustry shaft, paddle and bearing made
of stainless steel and the plastic-coated
bearings withstand the hardest condi-
tions. Detachable equipment heads
Versatility of application:
Rugged level measuring technique
further simplify installation and drive re-
placement; adjustment and calibration
as in other measuring methods are not
required.
Laser measuring systems: Acquisition
of output quantities and stockpiles
If bulk materials are transported on con-
veyor belts, the volume flow can be meas-
ured with the rugged BULKSCAN laser
measuring system from SICK MAIHAK
contact-free, exact and cost-effective.
The system can be used as warning sys-
tem to monitor belt utilization as well as
early detection of the center of gravity
position of the bulk material to prevent
operational malfunctions. Advantage:
existing conveyor belts can be equipped
without problems and at low effort with
the BULKSCAN.
Principle: a pulsed, fan-shaped laser
beam as a feeler scans the bulk mate-
rial surface and captures the object con-
tours as an entity. First of all, the bulk
material profile in the scan level is de-
termined from the time between trans-
mission and reflection of the laser beam.
The relative cross-sectional area is then
calculated from the comparison against
the profile of the unloaded conveyor belt.
Using the belt speed and bulk material
density, the actual bulk material volume
throughput and/or mass throughput or
overall volume/overall mass through-
put can be calculated and output just
as required. Output variables and limit
values can be specified in advance using
a computer. For example, the user can
log output quantities, settle daily totals
as well as optimize conveyor belt load-
ing, utilization and speed.
The BULKSCAN system is suitable
for use in the building industry, mining
industry and wherever bulk materials
are transported in open systems and the
bulk material quantity must be meas-
ured. The laser measuring systems from
LASE SICK can be also used when bulk
material stockpiles are to be measured.
They complement the product range and
extend the application spectrum of the
LMS laser scanners from SICK.
SICK MAIHAK thus provides compre-
hensive solutions from a single source
for all requirements and special features
of bulk material measurement.
Hanover Trade Fair: Stand F17, Hall 16
34 1/2007
No other is as complete and competent
Optical distance sensors for optimum solutions
As the number one in distance meas-
urement, SICK offers by far the broad-
est portfolio of opto-electronic sensors.
Whether short distances in the -range
or distances of several hundred me-
tres the right solution is available for
every task.
34
>> The choice is constantly growing: new
sensor solutions are added to meet new
distance measurement demands. The
best examples are the DT20 Hi analogue
distance sensor and the DS30 switch-
ing distance sensor (see Page 41) which
receive their debut at the Hanover Trade
Fair 2007.
When precision is decisive
Short measurement ranges between
2 mm and 300 mm depending on the
device and accuracy values in the
-range characterise the area of use of
displacement sensors, e.g. the OD, OD Hi
or OD Max. Difference measurements,
e.g. dynamic sheet thickness meas-
urements, can be carried out with the
OD Max system. Displacement sensors
are classically used in the most varied
of industries, e.g. the electronics or au-
tomotive industries, in which maximum
quality is great valued.
When the price-performance ratio
is the main factor for short to
medium distances
SICK also offers the classic triangula-
tion sensors for smaller measurement
ranges of up to 1,000 mm. Properties
such as teach-in and high repeatability
accuracies of a few mm open up typical
areas of use for filling level detection in
cassettes, or the regulation of slack in
tubes or webs, with sensors such as the
DT2, DT10 or DT20 distance scanners.
Ideal for medium distances
Scanning distance sensors with laser
light and time-of-flight measurement
are used over ranges of typically 0.5 m
to about 160 m. The sensors measure
directly on the object, e.g. a coil, a car
body or in a storage bay. Unlike other
processes used for time-of-flight, SICKs
opto-electronic sensors, such as the
DS60, offer maximum possible immunity
to ambient light and precise background
suppression even for dark or critical
surfaces, or small objects. The distanc-
ing of objects, vehicles or cranes for
collision prevention; contour detection;
the continuous detection of the winding
diameter of, for example, paper or steel
coils; the measurement of stack heights;
and difference measurements are typi-
cal tasks for scanning distance measure-
ment sensors such as the DS30, DS60,
DS500 or the DMT10.
Reflector systems for long ranges
The reflector distance measurement
systems of the DME and DML series are
best suited for long distances in ex-
treme cases up to 1,100 m. They do not
detect objects directly, but and hence
the name a reflector or a reflective foil.
This ensures a stable and optimised re-
flective behaviour which, in turn, allows
the measurement of longer distances
(against comparable sensors) than in
: Technology Distance measurement
Distance to object
Medium distance
Long distance
Short distance
high measurement accuracy
35
No other is as complete and competent
Optical distance sensors for optimum solutions
35
A further technological lead in distance measurement
Shining results: the new DT20 Hi distance sensor
Reliability regardless of materials, colours and reflectivity properties; hitherto un-
paralleled immunity to ambient light; precise; user-friendly; versatile the new
analogue DT20 Hi distance sensor shines in all applications, and has what it
takes to be the best in its class.
: Technology
Reliable solution for numerous
distance applications
SICKs great experience in distance
measurement with the broadest prod-
uct portfolio of its type, from the -range
to km distances is reflected in the
DT20 Hi. In classic applications, such
as the regulation of winding processes,
the positioning of gantry units, the clas-
sification of screws and other compo-
nents, or surface quality inspections, the
analogue distance sensor offers a variety
of functional reserves. But in innovative
applications, too, such as the automatic
laying of flooring and tiles, SICKs laser
scanners represent a reliable solution. It
is quite likely that the DT20 Hi, thanks
to its precision and user-friendliness,
will open up many more areas of use in
future .
And a propos user-friendliness: you
can find out for yourself just how quickly
and easily the DT20 Hi can be prepared
for use just click on www.sick.com/
dt20hi_setup and the animation starts
automatically.
insightLINK
INFO 126
>> Further reading
Further information on a new
distance sensor can be found
on Page 41
>> The DT20 Hi has a leading position
in the short- to medium-range distance
measurement market segment. Its la-
ser light transmitter and CMOS receiver
element master almost all surfaces
from white to black, from matt to glossy
and ensure extremely high immunity
to ambient light. The three versions, for
the measurement ranges of 50 150
mm, 100 300 mm and 10 600 mm,
offer top values regarding accuracy (up
to +/0.5 mm), reproducibility (up to
+/0.2 mm) and resolution (< 0.1 mm).
A display shows the particularly user-
friendly Setup menu. The new type of
plug concept allows connection of the
sensor at any angle through 90. Dur-
ing operation, the robust metal housing
protects the sensor from mechanical
stresses.
normal scanning operation. Handling
and conveyor systems represent a major
field of use for these devices, e.g. for the
distancing of vehicles or for determin-
ing the position of high-bay stackers in
automatic warehouses. The DME5000,
a distance measurement system for
these applications, is available in differ-
ent measurement range variants that
are specifically optimised for use in au-
tomatic small part stores or for high-bay
pallet warehouses.
Distance sensors best by
far from a single source
Only those who offer a wide range of
products can best master individual
tasks. Which opto-electronic solution
is optimum depends on the measure-
ment task and the circumstances. The
brochure Distance measurements in
all their varieties, published by SICK,
provides initial selection assistance and,
together with competent advice and the
complete solution portfolio, leads to by
far the best application results.
36 1/2007 36
Identification of the second dimension
Optimum solutions for
direct-marked codes
The demand for reliable identification verification, for gap-free traceability of parts,
or for dependable production control nowadays necessitates the use of 2D codes
such as Data Matrix. The trend here is increasingly towards Direct Part Marking
(DPM), the direct marking of objects by means of laser, dot peening, inkjet, or
chemical etching.
: Technology
>> Whether for production control,
the identification of circuit boards, the
allocation and traceability of laboratory
samples, document handling or protec-
tion against fakes the identification
of two-dimensional DPM codes almost
always makes special demands of the
reading technology. Thus differing sur-
faces, highly reflective or weakly con-
trasting backgrounds, different marking
techniques and small codes are typical
conditions faced by reading devices.
The right reading device is available for
each task with stationary and mobile
2D code readers from SICK.
Stationary reading with the ICR series
SICKs stationary 2D reading devices
always have DPM codes reliably in
sight. The ICR840 has been devel-
oped for the reading of 2D codes on
objects at a standstill or moving at a
slow speed. The integrated megapixel
sensor allows the most varied of DPM
codes to be read.
DPM code reading really gets moving
with the ICR85x, which has been spe-
cially designed for applications in which
the objects, and therefore the codes, are
in motion. Thus the ICR855, for example,
can identify codes at object speeds of up
to 10 m/s regardless of their cell size.
The ICR85x is used, in particular, for the
identification of direct-marked circuit
boards.
The ICR860 is far-sighted: it can
achieve reading distances of about 2 m.
The combination of differing lenses and
illumination units gives the system maxi-
mum flexibility and thus allows individual
adaptation to the particular application
and the DPM technique used.
Mobility is trumps
for the 2D hand-held code readers of
the IT series. The IT4600g and IT4800i
device series are ideal for the detec-
tion of 2D codes on standard labels.
The hand-held scanners of the IT6300
DPM series are available for the identi-
fication of directly attached codes. The
devices illumination can be individually
adapted to the particular reading situa-
tion. Thus, for example, individual illu-
mination elements can be deactivated
to create dark field illumination, which
is often required for the identification
of dot-preened codes.
Find out more and win
Whether standard labels or DPM
SICK offers solutions for the most var-
ied of sectors and the most varied of
applications. Visit the Internet page at
www.2D-code.com to find out more or
to get in contact with experts at SICK.
And use your chance to win an IT6300
DPM hand-held scanner the mobile
specialist for DPM codes.
A mobile hand-held 2D code scanner of the IT6300 DPM series
The stationary ICR850 2D code reading device
2D code reading devices
insightLINK
Further information on the Internet at:
www.2d-code.com and
37
Single-camera system for 2D
and 3D image processing
Smoothing the path from
inspection to analysis
Image processing technology departs from classical thinking on 2D and 3D
imaging with the Ranger C and Ranger E series. The cameras multiscan and scat-
ter functions combine complex analytical potentials in a single vision system.
37
>> Presence, alignment, contrast, bright-
ness and other conventional features
are predestined for 2D inspections. 3D
systems are involved if position, volumes
and shape require inspection, or spatial
measurement tasks have to be solved.
Users can often only combine the two
of them in a single system at consider-
able cost and using a lot of space. The
high level of complexity of the complete
solution thus created is frequently seen
as a further obstacle. If it is necessary
to inspect semi-transparent surfaces,
the choice of industry-oriented solutions
on the market is limited or the camera
solution must be supplemented by fur-
ther inspection systems.
Multiscan and scatter the fourth
dimension in image processing
The Ranger C and Ranger E camera sys-
tems from SICK IVP offer the necessary
technologies multiscan and scatter
for tasks in which the detection of both
an objects geometrical 3D data and its
conventional 2D features are necessary
in a single step.
The multiscan functionality permits
the simultaneous application of the
most varied of image capture processes.
Objects are simultaneously and with
a single image-capture process sub-
jected to a 3D detection, a conventional
2D inspection and, for objects with semi-
transparent surfaces, a scatter inspec-
tion. In the case of technical or organic
materials, this process obtains informa-
tion on the direct object surface. The
depth of penetration and light scattering
provides, in the form of measurement
values, information on the consistency
of the surface or the underlying object
or layers.
Latest image processing technology
in a complete package
A single camera, Ranger C or Ranger E,
is required for all these analysis tasks.
It takes on simultaneous tasks for a
variety of applications in differing areas
of the camera chip, and carries out pre-
processing. The resulting images are
transferred to an evaluation PC line-by-
line without any loss of time. Here they
: Technology
are available for the most varied of
simultaneous analyses.
Just one camera, a compact inspec-
tion structure, rapid image generation
for a variety of tasks, and immediate
availability of the measurement results
multiscan and scatter smooth the path
from inspections to the analysis of ob-
jects. Ranger C and Ranger E are thus
the new dimension in industrial image
processing.
Multiscan mode allows the capture of
a single image with several differing
illumination scenarios at the same
time and thus makes different in-
spection tasks possible in a second.
Advantage: One inspection position,
one inspection cycle, one vision sys-
tem for multiple criteria
white light
lasers
field-of-view
scatter (surface)
inspection
3D laser triangulation measurement
common gray scale analysis
Image processing
insightLINK
INFO 127
www.sickivp.com and
38 1/2007
: Interview
New EN ISO 13849-1 and EN 62061 controller standards
Nothing to fear from the standards duo
The tried-and-tested EN 954 standard will only continue to apply for the evaluation
of safety control systems for just under three years. Then it will finally be replaced
by the edited version of the EN ISO 13849-1, which is already valid. EN 62061, how-
ever, also applies now when the safe design of electrical controllers is concerned.
What does the standards duo mean in practice? And why are there two standards
for the same subject? Which standard should machines constructors and plant
users employ? Dr. Michael Schaefer and Michael Hauke from the Trade Association
of Industrial Safety (BGIA) provide SICK insight with a full explanation.
SICK insight: What are the general tasks
of the Trade Association of Industrial
Safety, particularly with regard to stand-
ards?
Dr. Schaefer: The BGIA, with about
250 employees, is a central research
institute of the commercial trade asso-
ciations. Our tasks include research into
safety at work; advising trade associa-
tions, member works and federations;
and testing and certifying, in particular,
new technologies for which no standards
yet exist. We develop principles for the
application of recognised scientific proc-
esses and their transfer for practical use.
Closely connected with this is participa-
tion in the creation of standards, which
provides a concrete practical reference
to regulations that are formulated in ab-
stract terms. The new EN ISO 13849-1,
as the successor standard to the familiar
EN 954, is an example of this.
SICK insight: Why is or was the proven
EN 954 no longer up to date and why is it
being replaced by EN ISO 13849-1?
M. Hauke: Despite all the updating that
has taken place over the years, EN 954
was increasingly coming up against its
technological limits. Although appli-
cable for programmable systems and
complex electronics, it contained no
detailed demands. Reliability values for
individual system components, and the
quality of testing measures, could not
be sufficiently taken into account during
categorisation. Finally, the topic of com-
plexity was not included and the risk of
system failures generally rises with the
number of its components. All in all, the
consideration of failure probability as re-
quired, for example, by the fundamental
IEC 61508 electrical safety standard,
was not sufficiently brought to the fore.
The new EN ISO 13849-1 complements
the familiar assessment criteria with
additional values, e.g. the reliability of
components, the quality of testing, or
susceptibility to multiple faults. Faults
are now not merely counted the proba-
bility of their occurrence is calculated on
the basis of device characteristics. Thus
the categories of the EN 954 are now re-
flected in the Performance Levels of the
EN ISO 13849-1 with additional content.
SICK insight: The EN 62061 was created
practically parallel to EN ISO 13849-1.
Tautology? Or where do the differences
lie?
Dr. Schaefer: Thats right, both stand-
ards were largely driven forward simul-
taneously. We are dealing with two dif-
ferent standards worlds: that of machine
construction and that of electrotechnics.
While the EN ISO 13849-1 has principally
been designed as a comprehensive and
practicable standard for safety-oriented
parts of controllers for machine construc-
tion, the EN 62061 (as a sector standard
for IEC 61508) provides a framework for
the functional safety of safety-oriented
electrical control systems and their
sub-systems in machines. It succeeds
Whether EN ISO 13849-1
or EN 62061 in the
matter of machine safety
both paths ultimately
fulfil the aim
Dr. M. Schaefer
Dr. Michael Schaefer (left) and Michael Hauke in a good mood during the interview
39
: Interview
in making the statistical processes, and
the electronics themselves, acceptable
in safety technology internationally. It is
thus, among other things, of interest for
the development departments of safety
technology producers. Highly electronic
systems, however, are also sometimes
acquired because of the non-applicabil-
ity of pneumatic, hydraulic or mechani-
cal systems; the complex calculation
process; or the wide-ranging obligation
for documentation which can, in extreme
cases, extend to several hundred pages,
among other reasons.
SICK insight: What should machine
producers and plant users orient them-
selves upon?
M. Hauke: We recommend the EN ISO
13849-1 for machine constructors. It
covers all the technologies, is logical and
practical for smaller and medium-sized
companies and, in many cases, con-
tains a clear reference to an applicable
C-standard. Categorisation into B, 1, 2,
3 and 4 is already understood in princi-
ple and its improvement with regard to
the reliability, structure, robustness and
diagnosis of safety technology is more
comprehensible. Whereby the column di-
agrams developed by the BGIA also help.
Large companies, and most producers of
safety technology, use the EN 62061 in
parallel because the increased effort
can, under certain conditions, result in a
slightly better evaluation. This pays when
high unit numbers are involved, or when
the target application is not precisely
known. Both roads, in effect, reliably
lead to Rome.
Dr. Michael Schaefer from Department 5
of the BGIA Accident Prevention/Product
Safety
insightLINK
You can obtain further information
about the BGIA at:
www.hvbg.de/bgia
SICK insight: Where and how can pro-
ducers, users, planners or inspection
personnel find out more?
Dr. Schaefer: There are a range of pos-
sibilities. Companies like SICK offer thor-
ough specialist seminars on all aspects
of the new standards situation. Groups
like the VDMA, the ZVEI or the technical
monitoring associations make similar
offers. We in the BGIA are rather less
directed towards the end users, and fol-
low the train the trainer philosophy, i.e.
we focus on multiplicators in organisa-
tions. What we do offer any interested
producer or user, however, is a variety
of tools for these standards, e.g. at
www.hvbg.de/bgia (WebCode 1674855).
The spectrum ranges from a disk on
calculating the Performance Level, up
to our SiSteMa freeware (which will be
available in the second quarter of 2007),
with which users can determine the safe-
ty of machine controllers on a PC using
the EN ISO 13849-1. A new BGIA report
is planned for autumn, dealing with the
topic of standards for safe control sys-
tems and containing about three dozen
examples of circuits and calculations.
SICK insight: A final question: do the
two standards have a joint future will
there sometime be THE standard for
safe control systems?
Dr. Schaefer: Standard dualism means
complexity and users, in particular, un-
derstandably do not like this. There are
therefore efforts underway to combine
the contents of the EN ISO 13849-1 and
the EN 62061 in a single standard. But
because this cannot be achieved over-
night, users should decide on one of
the two alternatives on the basis of their
specific interests. What is certain is that
both standards lead to a comparable
safety level though via differing routes
and with differing levels of effort.
SICK insight: Dr. Schaefer, Mr Hauke,
thank you very much for this conversation.
>> BGIA facts and figures
The Berufsgenossenschaftliche Institut fr Arbeitsschutz
(Trade Association of Industrial Safety) is a research and testing institute
of the commercial trade associations with 250 employees, based in
Sankt Augustin near Bonn.
The BGIA supports the commercial trade associations and their
institutions, particularly in scientific-technical questions regarding
health and safety at work.
The BGIA maintains close contacts with foreign safety at work institutions.
There are regular exchanges of experiences with a group of 23 research
institutes involved in health and safety at work in 20 nations, regarding cur-
rent developments and resulting in statements on concrete co-operations .
P
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: HMI Special
40
SICK presents sensors for factory, logistics and process automation
>> As one of the worlds most innova-
tive sensor suppliers, we show you tech-
nological highlights and numerous new
products.
Win with SICK
We show you how you can most quickly
implement the solutions you need for
your automation tasks. And incidentally,
you can win a navigation system for all of
Europe. So it pays to drop in at SICK.
Visit us in Hall 9 a varied pro-
gramme awaits you. And, as always,
there is no lack of entertainment. Our
trade fair party starts at 6.00 p.m. on
Thursday 19 April. There will again be
top-class music and your physical well-
being will also be catered for.
More on the HMI 2007 at
www.sick.de/hmi
Visit us at
Stand F54, Hall 9
We look forward
to your visit.
Numerous technological highlights in almost 1,000 m
2
WELCOME TO
HANOVER 2007
With a hitherto unparalleled variety of applications, SICK is this year showing the pos-
sibilities offered by sensors, safety technology and identification solutions in industrial
automation. Solutions for almost all industrial sectors can be seen and we intend to
present them to you live.
News & Highlights p News & Highlights p News & Highlights p News & Highlights p News & Highlights p News & Highlights
1/2007
Partner Portal
News Arena
Logistics automation
Info
Sensor Solutions for
Factory Automation
safetyPLUS
Overview
Motion & Drives
Personnel
41 41
: Products
>> This combination, currently unique
on the market, marks the onset of a new
age that of the time-of-flight.
Precise, reliable switching,
always available
It would hardly be possible for the DS30
to cover a more diverse range of appli-
cations. Even extremely dirty pallet feet
are reliably detected when checking the
occupancy of storage bays in handling
and warehousing systems. In package
distribution centres, packages of all siz-
es and colours are reliably detected at
distances of up to 2 m, e.g. to trigger bar
code reading stations. This small sensor,
with its large functional reserves, offers
More highly sophisticated distance sensor
Time-of-flights time has come
Extremely accurate distancing, the maintenance of distances, the checking
of presence these tasks are ideally solved with the new DS30 distance sensor.
As compact as a photoelectric switch, the device offers a scanning distance of 2 m
and highly precise background suppression regardless of the objects colour.
versatile use even in the harsh environ-
ments of the rubber, paper and steel in-
dustries.
New time-of-flight age
with perfect background suppression
The DS30 is the first device to measure
the time-of-flight using a completely new
type of electronic evaluation process. The
high resolution and reproducibility thus
achieved gives the DS30 its high level of
precision and reliability even with low
object reflectivity. The background sup-
pression is absolutely perfect: nothing
can interfere with the DS30s distance
measurement. This is particularly im-
portant when the sensor is aligned in
:

T
I
T
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T
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insightLINK
information on the Internet at:
open spaces, e.g. on conveyor systems
or high-bay stackers. Whether reflective
metal beams in the shelf construction,
vehicles with reflectors passing by, or
personnel with reflective safety jackets
there is no spurious switching with the
DS30.
Distance measurement with the
DS30 because its technological lead is
nothing less than the distance to a sec-
ond-best solution.
The very best a new masterpiece
amongst distance sensors: the DS30
>> Further reading
You can find further information on
distance sensors in the Technology
section on Pages 34 and 35
Distance sensors
42 1/2007 42
: Products
>> The challenge of a reliable glance in
the box is not new previous solutions,
however, were often complicated and
not always as reliable and maintenance-
free as could be desired. Laser meas-
urement technology, in the form of the
LMS400, now allows the reliable detec-
tion of even small objects with difficult
detection properties in moving contain-
ers with an all-in-one sensor.
Column(s) of process reliability
The compact LMS400 is installed above a
conveyor system and generates a meas-
urement field that is divided up and evalu-
ated in the internal processor as either
equidistant or overlapping columns. As a
result of almost parallel laser illumination
there are no areas of shadow that could
impair detection, e.g. at the edge of a box.
With a resolution of 1 mm and a measure-
ment accuracy of 4 5 mm, even objects
of only 30 x 30 x 30 mm
3
(roughly the size
of a golf ball) are reliably detected. Thus
the system functions like a scanning light
curtain or a parallel arrangement of individ-
ual photoelectric proximity switches but
Scan, detect, switch
A quick look in the box
Is whatever should be in the box actually
there? This tantalising question is often
posed for a variety of containers during
picking, packaging, despatch or return
of goods. It is reliably answered by the
LMS400 laser measurement system
with Level Control.
is much more compact, and offers much
simpler installation and maintenance.
Furthermore, the application can be imple-
mented with the help of user-friendly setup
software in the scanner itself. The LMS400
can immediately provide information for a
plant computer, or control a sorting gate,
via its digital switching outputs.
High-level logistical processes
Whether distribution centres; mail order
companies; courier, express and pack-
age service providers; breweries; dairies;
or food producers the LMS400 raises
logistical procedures to a new level of
process and cost efficiency.
On Page 18 you can read about
how the LMS400 helps a Swiss auto-
motive service provider to prevent im-
pairment of its quality and image, while
also avoiding high costs due to over- or
under-delivery.
:
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New series of photoelectric switches in miniature standard housing
Compatible mounting, rapid action, short-range suitability
>> The series includes the WL8 photo-
electric reflex switch and the WTB8
photoelectric proximity switch (which
is also available as the WTB8L with
laser optics). The conventional hous-
ing design with its mounting slots
offers compatible mounting ensuring
easy upgrading to this powerful sensor
technology.
Performance counts
Whether in storage and conveyor sys-
tems, in packaging or vending machines,
or in print and paper it is the perform-
ance that matters in the various tasks.
The photoelectric switch has a range
of 4 m. The scanner, with background
suppression, operates reliably at up to
300 mm. The switching frequency of
up to 2 KHz allows the solution of rapid
applications. The photoelectric switchs
autocollimation principle eliminates
dead zones at close range to the sensor,
even when reflective foil is used. It also
permits the use of small shutters.
The new W8: install, connect, automate.

SICKs new photoelectric switch series is called the W8. Autocollimation, back-
ground suppression and high switching frequencies open up a wide range of
applications for these compact sensors.
Further information for downloading
can be found in the Literature Finder
at www.sick.com
43 43
: Products
Motorised roller sensors with expanded logic functions
Always alert when it matters
Rest when the conveyor section is empty, and wake up when the goods come: the
WTR photoelectric proximity switch and the WLR photoelectric reflex switch can
control motorised rollers autonomously. This increases the rollers service life and
reduces operating costs.
:
P
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W
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vate the subsequent conveyor segments
in the direction of transport. Sleep mode
resumes when a particular accumula-
tion area is empty again, restoring the
energy-saving and cost-cutting quiescent
phase.
Vis--vis costs: the sensor and logic
functions of the WTR and WLR are ac-
commodated within a single housing
both devices are thus well aware
when it comes to reduced installation
and mounting effort.
>> All Gateways use SICKs Enhanced
Function Interface (EFI) for integration.
A variety of versions of the S300 and
S3000 safety laser scanners, the C4000
safety light curtain, the M4000 multiple
light beam safety device, the UE403, and
the UE440/UE470 safety controllers can
be connected.
Integration increases
plant availability
This integration solution allows the use
of the expanded sensor functions of
SICKs ESPEs, e.g. the monitoring field
switching function of the safety laser
Safety technology and standard automation technology come together
New network gateways for electro-sensitive
protective equipment
scanners. The Gateways are suitable for
both standard and safe PLCs. Integra-
tion of SICK devices with the help of the
new Gateways allows the bidirectional
transfer of status information, as well as
configuration and diagnostic functions,
within the particular fieldbus environ-
ment via the Gateways. This permits
complete system diagnosis and simple
reconfiguration at any time. Integration
in a human-machine interface (HMI),
and the possibility of the remote main-
tenance of safety systems, lead to a sub-
stantial increase in plant availability.
INFO 128
SICK presents a new product family, called UE-EFI Gateways, for the integration
of electro-sensitive protective equipment (ESPE) and safety controllers in
PROFIsafe, PROFIBUS-DP, Ethernet TCP/IP and CANopen bus systems.
The WTR with logic
functions (single feed,
single discharge, sleep
mode, awake mode) for
controlling motor rollers
>> In addition to the familiar functions
of single feed and single discharge,
the new WTR and WLR (for extremely
reflective surfaces) now offer a sleep/
awake operating mode. This permits
need-oriented control of motorised
rollers with a 24 V DC operating volt-
age, such as the RollerDrive EC300
from Interroll
. There is no need for

any complicated external programming
of the logic for the accumulating roller
function.
Sensor controls motorised rollers
The motorised rollers are in sleep mode
when the conveyor section is empty. A
transported object approaching the sen-
sor is detected and the awake mode
brings the motorised rollers to life. Accu-
mulating roller sensors successively acti-
The Interroll
RollerDrive EC300
for controlled acceleration, braking,
and constant speeds
44 1/2007 44
: Products
>> The UE410 Flexi considerably sim-
plifies complex control configurations.
Based on a Main Unit, almost any fur-
ther input and output modules can be
added the control solution grows with
the particular safety task. A communi-
cation module for all common fieldbus
environments allows integration of the
UE410 Flexi in the customers existing IT
network. All modules communicate with
one another via a data bus. The function
of each module can be selected using
a rotary switch on the front panel the
screwdriver has replaced software as a
system prerequisite.
Users are full of praise
The success of the UE410 Flexi is no
accident. Users praise the low number
of components needed, the substan-
tially reduced space required and,
Flexibility and function configurator make safety controller popular
When safety logic manages
without software
Only on the market for a few months and already several thousand are in operation
the UE410 Flexi modular safety controller has rapidly become a real sales hit. Its
success is the result of both its flexible, multifunctional modular principle and its
function configurator being available on the Internet.
frequently , the lack of logic and diagnos-
tic wiring. The function configurator at
www.ue410flexi.com, which minimises
the advance engineering effort, is par-
ticularly helpful during the construction
of control solutions.
Unique: agile Flexi function
configuration via drag & drop
The Flexi configurator is a graphic tool,
supported by application animations,
for displaying and selecting sensors and
control functions. It helps in the selec-
tion of the required components or mod-
ules at the click of a mouse. The com-
plete range of safety sensors from SICK
is shown in a pull down list, and they can
be transferred by drag & drop to the con-
figuration being created. The configura-
tor shows which UE410 Flexi control
modules and which switch position can
insightLINK
INFO 117
www.ue410flexi.com
be used to implement which functions.
AND/OR, muting or bypass provide con-
trol flexibility, as do emergency stop with
and without cross-circuit detection, two-
hand applications, protective door moni-
toring or adjustable response time. The
user can change the modules internal
logical functions on the screen by click-
ing on the rotary switch. The configura-
tor shows brief product- and function-
related descriptions, and displays the
overall control configuration previously
created. When the Flexi control solution
is finished it can be stored for subse-
quent processing, or saved as a graphic
in .PDF format.
It really has never been as easy for
users to construct their own individual
safety solution. The Flexi configurator
shows how straightforwardly and
also provides the necessary order infor-
mation!
The Flexi configurator graphically
permits the construction of individual
safety solutions
Modular safety controller
45 45
: Products
The new IT4820i radio hand-held scanner opens up a wide range of mobile indus-
trial applications. This has been enabled by the latest generations of Bluetooth
data radio and imaging technology. They give the device mobility and excellent
reading performance.
>> Thanks to the fifth generation of the
powerful Adaptus
TM
imaging technology,
the IT4820i reads both 1D and 2D codes
as well as symbols, signatures and im-
ages. Thus almost all labels common in
transport, logistics and other industrial
processes can be reliably detected.
Reliable data handling
A Bluetooth V1.2 radio module ensures
transmission of the reading information
in a cable-free network. Users can work
online within a radius of 10 m from the
basis station. Outside this range, any
codes scanned are stored temporarily in
the device itself and automatically trans-
mitted to the basis station on re-enter-
ing radio range. The adaptive frequency
hopping process protects data transfer
from interference from the surround-
ings, while also ensuring that channels
already occupied (e.g. by W-LAN) are not
interfered with.
Practical: battery
changes without tools
The modern lithium ion battery allows up
to 50,000 scans per charge. Replace-
ment batteries can be charged separate-
ly. It is particularly easy to replace a bat-
tery in the IT4820i. The battery compart-
ment in the handle has a small wheel for
opening it no tool is now necessary for
changing the battery.
Robust housing technology, allow-
ing reliable function even after being
dropped 50 times from a height of 2 m,
and powerful scanning performance
make the IT4820i a dependable device
with long availability even under harsh
operating conditions.
insightLINK
or as a .PDF in the Literature Finder at
www.sick.com
Radio hand-held scanner
Bluetooth hand-held scanner for industrial use
Mobility and reading
performance guaranteed
46 1/2007 46
: Products
SICK has expanded the IVC-3D smart camera with functionalities for the three-
dimensional visual guidance of gripping systems and robots. Large and small
objects, objects at rest or in motion, parts with and without positioning and align-
ment tolerances the cameras visual power ensures targeted gripping under all
conditions.
>> Three-dimensional vision for guid-
ing grippers and robots is required
when there are no grip-relevant object
features and position information is
lacking or their presence is not re-
producible. Contrast problems can also
lead to users deciding to exploit a 3D
camera system if damage to products,
or spurious gripping during automated
handling, must be reliably ruled out.
The IVC-3D offers new possibilities,
both during picking from conveyors or
gripping from pallets, thanks to the in-
tegration of highly precise functions for
the evaluation and synchronisation of
measurement co-ordinates. Calibration
between the smart camera and the ro-
bot or handling system has been made
considerably easier. A simply construct-
ed calibration tool allows the camera
and robot to obtain the same spatial
co-ordinates and generate from them
a shared co-ordinate system for their
working space.
Picking from conveyors:
often with small parts in motion
Primary packaging (e.g. of biscuits) in-
creasingly involves the use of automated
gripping systems. The parts are small, in
motion, unaligned, and their geometri-
cal and colour properties often differ.
In extreme cases they offer almost no
contrast to the conveyor belt. The IVC-3D
reliably solves the task of object detec-
tion under these, for 2D cameras, very
problematic conditions. It supplies all
the object information that is necessary
for reliable gripping even its position
and alignment on the conveyor belt. Tak-
ing the conveyor belt speed into account,
the picking system can exploit this infor-
mation for rapid and millimetre-accurate
gripping.
Gripping from the pallet:
large parts at rest
Without optical guidance robots can
only grip objects if their dimensions are
known and their position and orientation
defined, e.g. by means of a retaining or
centring system. The IVC-3D removes
these restrictions. As a moving unit,
the smart camera can detect the posi-
tion, height, orientation, alignment, and
height level on the pallet even with
complex objects. It is also possible to
detect surface properties, as well as
identify and sort objects on the basis of
geometrical features, e.g. in order and
not in order. Thus the IVC-3D can pro-
vide the robot with two types of informa-
tion: for the actual gripping process, and
for process-oriented handling.
A robot needs excellent vision for accu-
rate gripping hence the IVC-3D.
insightLINK
INFO 129
www.sick.com/insight/en and
www.sickivp.com
3D smart camera for picking systems and robots
Spatial visual power for
targeted gripping
3D camera system
47 47
: Products
Safety light curtain in specific variants
Product relaunch C2000: theres always
a suitable solution for Category 2
The new Category 2 C2000 RES/EDM
light curtain in the C2000 product
family is now even easier to integrate
in the machine or plant. Its range of
functions is tailor-made for special
customer requirements.
insightLINK
INFO 130
Integrated functions and status information permit rapid commissioning
and prevent unnecessary machine downtimes the new C2000 RES/EDM
safety light curtain
>> With their high signal reserve, the
C2000 family of safety light curtains
also operate reliably under harsh indus-
trial conditions. Functions and status in-
formation integrated in the device per-
mit rapid commissioning and prevent
C2000 RES/EDM
exploiting savings potentials
The C2000 RES/EDM is an interesting
variant regarding cost savings for the
system solution. Two auxiliary contac-
tors are considerably cheaper than one
safety relay. This is where the C2000
RES/EDM offers users savings poten-
tials. Why: the switching behaviour of
the auxiliary contactors is monitored by
the light curtains External Device Moni-
toring function. Thus the use of a safety
relay for this function is unnecessary.
Integration of the machines Reset re-
lease takes place at a reasonable price
via a standard cable further reducing
the cost of the safety system. This vari-
ants proven 7-segment display, with its
information on status and errors, pro-
vides important information preventing
C2000 RES/EDM one example from
the large C2000 family of products that
shows the range of individual solutions
available.
Safety technology
48 1/2007 48
: Products
Efficient, despite difficult contrasts
Laser contrast scanner for
fine and distant contrasts
Its small light spot and long scanning distance make the new KT8L a versatile
solution for detecting fine and distant contrast marks. Teach-in is particularly com-
fortable thanks to its simplicity and a bar display showing detection quality.
>> A laser LED and autocollimation give
the KT8L a scanning range of from 30 to
800 mm with full depth of focus. The au-
tocollimation principle provides another
advantage: the small light spot on the
object or contrast mark, even at long
distances. Depending on the device ver-
sion, spot diameter is either 3 mm or
0.3 mm the latter permits detection
of even the smallest print marks and
labels. The small light spot allows bar
codes, for example, to be read even at
long distances.
User-friendliness guarantees reliability
Contrast scanners detect grey value dif-
ferences on objects, e.g. print marks
on newspapers, magazines or packag-
ing. The reliable detection of grey value
contrasts, e.g. the brightness difference
between a mark and its background,
is of decisive importance for detection
quality. With its simple adjustment via
teach-in, the KT8L is fit for any contrast
program. Users can check the device
directly: they can determine signal qual-
ity during commissioning and operation
by means of the integrated bar display
and, if necessary, make readjustments.
The analogue output provides a signal
of 0.15 10 mA. The switching signals
are available as a NPN- or PNP-switch-
ing output, depending on the device ver-
sion selected.
Easy installation,
industry-oriented design
The KT8L is easy to install because the
device has a pivoting M12 device plug.
In use, its industry-oriented design in a
robust metal housing with an enclosure
rating of IP 67 ensures availability of
the scanner. Immunity to impacts and
vibrations is guaranteed, according to
IEC 68.
Wide variety of uses
Its suitability for distant and fine objects
opens up numerous opportunities for
using the KT8L. The smallest of compo-
nents on electronic cards are just as re-
liably detected as transparent objects,
or the sell-by date on packaging.
Contrast detection with the KT8L when
fine details, long-sightedness and func-
tional reliability matter.
insightLINK
www.sick.com/insight/en and
www.laserlichtschranke.com
Small light spot and long scanning distance the new KT8L laser contrast scanner
Contrast detection
49 49
: Products
Scanning is quicker and more ergonomic
First class: the new-generation
hand-held bar code reader
The new IT3800g hand-held scanner is characterised by ergonomic design and
many improvements in handling and reading performance. Ideal prerequisites for
continuing the success story of the IT3800 family of linear imagers.
>> The IT3800g exploits the latest gen-
eration of linear imager technology. It
features considerably longer reading
distances, greater depth of focus and a
more intensive scanning line with better
insightLINK
www.sick.com
Very user-friendly handling
All features profit from handling that is as
easy and user-friendly as possible. Reliable
aiming on the object, a high tolerance of
movement, and immediate information on
positive reading results permit particularly
simple work with the device. The housing is
more ergonomically shaped and lighter. A
variety of interfaces, including for common
electronic till systems, permits smooth
connection of the hand-held scanner.
Robust design for rough use
The new IT3800g also sets the standard
regarding robustness: capable of func-
tioning even after 50 falls from a height
of 1.5 m in tests, and equipped with a
5-year guarantee.
All in all, the IT3800g hand-held scan-
ner is the ideal partner for mobile bar
code detection in trade; in production,
transport and logistics; or for processing
documents.
A world first
Now also for C-slots
The MZ2Q C-slot is the worlds first
teachable cylinder sensor for the
C-slot. Compact housing, two inde-
pendent switching points and sophisti-
cated electronics make the sensor the
optimum solution for applications with
very short pistons.
>> Two freely adjustable switching points
in a single sensor for the C-slot, too, this
now means lower installation effort and
less cabling on the pneumatic cylinder.
The compact and short sensor housing is
another plus: it allows completely sunken,
and thus protected, installation in the slot.
Easy teaching
The space-saving size of the MZ2Q
C-slot has been made possible because
the electronics are now no longer within
the housing but are integrated in the
connection cable. The easy teach-in
process for the two switching points,
for which no special teaching tool is
required, remains unchanged. Thus
the sensor is ready for operation in the
shortest of times.
Teach me twice: the sensor concept
of the MZ2Q is now also good for the
C-slot INFO 131
visibility on the bar code. Resolution has
been improved to 0.075 mm; evaluation
of the reading information now takes
place four times quicker than in the
predecessor model.
50 1/2007 50
: Products
Detection and measurement in the Age of Communication
First automation light grid
with IO-Link
The MLG automation light grid from SICK is now available with an IO-Link inter-
face. This allows integration of the sensor system in the fieldbus environment of
a machine or plant.
>> The MLG light curtain is an auto-
mation solution for measuring or pure
switching tasks. Among other things, it
offers a variety of beam separations (10,
20, 30 or 50 mm), monitoring heights
between 100 mm and 3,140 mm, and
two ranges of 0 5 m or 0 8.5 m.
Among the most interesting application
opportunities are the detection of object
heights (e.g. on a conveyor system or in a
storage bay), the regulation of web slack,
zone division and monitoring (e.g. to
monitor pick-to-light picking processes),
the classification of objects on the basis
of their size, and the checking of edges
and profiles.
IO-Link ensures comprehensive
exchange of information
All applications can profit from IO-Link,
i.e. integration of the MLG in the fieldbus
environment of a machine or plant. The
fieldbus coupling allows the automation
light grid to be detected and contacted
both at the operating panel of a machine
and in a distant control room. Digital
switching distances and digitalised ana-
logue values can also be transmitted, as
can a wide variety of supplementary infor-
mation such as contamination warnings,
the presence of sources of interference
in the MLGs vicinity, the quality of the
switching signal, the current scanning
distance or the sensors serial number.
Parameterisation, process and diag-
nostic advantages
The IO-Link option offers users of the
MLG a range of important advantages.
Parameterisation of the MLG can take
place directly from the automation sys-
tem of the machine or plant. Basic func-
tions such as height measurement, divi-
sion into zones, or the checking of pres-
ence can also be activated via IO-Link,
as can teach-in or the process-oriented
blanking of beams. The combination of
sensor and IO-Link provides important
insightLINK
INFO 132
www.sick.com/io-link and
Possible with the MLG IO-Link: integration of the sensor system in the fieldbus environment of a machine or plant
data during operation, contributing to op-
timised processes. Testing of the trans-
mission module is also possible, as is
the monitoring of sensor contamination,
synchronisation of the transmitter and
receiver, or ensuring optimum receiver
signals during the teach-in process.
Conversely , IO-Link offers the opportuni-
ty to contact the MLG from the controller
at regular intervals to check sensor func-
tion. This cyclical remote maintenance
allows targeted preventive servicing and
thus minimises machine downtimes.
The concept of MLG with IO-Link offers
a secure technological future and thus
long-term investment protection.
IO-Link
51 51
: Products
>> The MZ2Q is used for, among other
things, object detection on grippers,
clamps or presses, in which a pneumatic
cylinder with a piston length of up to 50 mm
acts as an actuator. The two freely adjust-
able switching points in the sensor allow
the reliable detection of defined end-posi-
tions, or the generation of an advance sig-
nal for targeted reduction of piston speed.
Thanks to the IO-Link, the definition and
monitoring of the switching points can be
carried out automatically and remotely
via fieldbus, e.g. by the machine control-
ler. The MZ2Q IO-Link has an individual
ID number for this purpose, making it ad-
dressable during communication .
The familiar advantages of the
standard MZ2Q remain unchanged:
short housing, space-saving and reliable
mounting in the slot, lower installation
and cabling effort, and high switching
accuracy.
The first magnetic cylinder sensor with IO-Link
Remote teach-in and diagnosis
The MZ2Q IO-Link is the first magnetic cylinder sensor that can be integrated into
a machines fieldbus environment. The two switching points can now be taught-in
and monitored remotely.
insightLINK
INFO 131
www.sick.com/io-link and
IO-Link
>> IO-Link on the march: users increasingly appreciate the benefits
SICK insight: Two years ago, SICK
first presented standard photoelectric
proximity switches that could be inte-
grated in fieldbus environments, and
the underlying IO-Link technology has
been a major talking point for about a
year now. How is IO-Link presented and
positioned on the market now?
Klaus Halder: SICK believes that
IO-Link technology, i.e. the reason-
ably priced expansion of a sensors
switching output function to create a
communication interface, now has a
Klaus Halder
Manager of the
Standard Sensors
Business Unit
greater potential than ever. The advan-
tages, including parameter download
from a machine controller, compre-
hensive remote diagnostic capability,
increased plant availability , automatic
plant documentation, and important
for the chemical and pharmaceutical
industries validation of the entire ma-
chine, right down to the sensors, show
how varied the operational advantages
of sensors with IO-Link can be. Interest
within many sectors is correspondingly
large, so that we expect a rapid spread
of the technology and its use in projects
soon to be implemented.
SICK insight: What strategy is SICK follow-
ing by expanding the IO-Link portfolio?
Klaus Halder: As a sensor supplier with
broad market access to the most varied
of customer segments, SICK is actively
reacting to current interests and trends.
We therefore already offer a compara-
tively wide range of IO-Link devices. So
we are presenting more new IO-Link
sensors again at the Hanover Trade Fair
2007. While optical binary devices, in
particular (e.g. photoelectric proximity
switches such as the third generation of
sensors from SICK), have dominated up
to now, we are also presenting for the
first time multi-bit sensors (e.g. the MLG
auto mation light grid), and non-optical
sensors (such as the MZ2Q cylinder
sensor) with IO-Link. The presentation
of IO-Link devices that are actually avail-
able will make it clear that SICK sees IO-
Link as one of the most important future
technologies for automation.
SICK Insight: Thank you very much for
this brief statement.
IO-Link sensor series available from SICK and presented at the HMI:
WTB4-3 IO-Link photoelectric proximity switch WTB18-3 IO-Link photoelectric
proximity switch WTB27-3 IO Link photoelectric proximity switch WL12G
IO-Link through-beam photoelectric switch for transparent objects IOLSH con-
nection module MLG IO-Link automation light grid MZ2Q IO-Link magnetic
cylinder sensor
52 1/2007 52
: Products
Best bus connections
New HIPERFACE
adapter modules
for CANopen and DeviceNet
Space-saving scanner for bar codes and 2D codes
Small + omnidirectional = ideal
>> Whether bar codes, 2D codes, or pure
image capture the ICR803 reads omni-
directionally, i.e. in any orientation. LED
illumination, the latest imaging technol-
ogy and the choice between USB or RS-
232 interface versions everything that
a device needs for reading is already in-
tegrated in the small 49 x 40 x 25 mm
3
housing. No external decoder, illumina-
tion or interface adapter is required. This
makes the ICR803 the latest product
in the ICR series based on camera tech-
nology the ideal identification solution
for automated analysis machines and
other small systems, handling equip-
ment and robots.
Objects must be identifiable in any alignment but mounting space for the
reading device is limited given these conditions, the small ICR803 code read-
er is enormous.
insightLINK
www.sick.com
SICKs rotative, linear and optical position detection systems with a HIPERFACE

interface offer the best bus connections. In addition to adapter modules for SSI and
PROFIBUS, versions for CANopen and DeviceNet are now available.
insightLINK
www.sick-stegmann.com and
>> They offer simple conversion of
HIPERFACE
data output from inte-

grated systems for path measurement
and position detection in every existing
fieldbus environment commonly found
in industry. One advantage of this is
that motor feedback encoders with a
HIPERFACE
interface unlike stand-

ard encoders offer very high resolu-
tions during the evaluation of digital
and analogue signals. A further benefit
is that the encoder itself remains com-
pact. It can be installed in tight spaces.
The bus adapter is then located wher-
ever more mounting space is available.
Integration takes place using M12 con-
nection technology.
Whether SSI, PROFIBUS, CANopen
or DeviceNe t all interface adapter
modules are available immediately and
worldwide.
53 53
: Products
Safety switches: product portfolio grows further
New housings and bus connections
SICK is presenting a total of four new safety switches and locking devices at the
HMI 2007 in Hanover. Smaller housings, AS-i device versions and more integrated
functions are the features required during practical operation.
>> Electro-mechanical and non-contact
safety switches are important elements
of SICKS overall safety portfolio. Togeth-
er with opto-electronic protective equip-
ment, safe control solutions and wide-
ranging safety-oriented services they
offer in line with SICKs safetyPLUS

philosophy complete safety solutions
over the entire life cycle of machines
and plant, involving constant innovation
and practical improvements to sensors,
switches and controllers.
i15 Lock: great safety in
small housings
The new i15 Lock safety locking device is
particularly compact. The housing length
has been reduced by up to 50% com-
pared to other locking devices (depend-
ing on the version of the mechanical or
electrical safety locking device). This is
advantageous wherever machines with
light doors or Plexiglas hoods require
monitoring. Depending on the robust-
ness of the door, SICK offers the i15
insightLINK
Lock with plastic or metal heads. The
safety switch is really big in functional
terms: it detects the opening and lock-
ing state of movable barriers and has a
retention power of up to 1,500 N.
i18-AS-i and i10 Lock-AS-i: safety
switches with direct AS-i Safety at
Work bus connection
The safety switches i18-AS-i (with a sep-
arate actuator) and i10 Lock-AS-i (safety
locking device) have been supplemented
with an AS-i Safety at Work interface. As
a result, their safety tasks can now be
directly integrated in a machines AS-i
network.
Safety switches with expanded
connection technology
In addition to connection via a cable
gland, the safety switches are now also
available with M12 plug-in connector
technology. Selected types even have
sockets for two plug-in connectors. In
this case it is now possible to connect
the contacts in series, considerably re-
ducing the installation effort.
i150RP wire-draw switch:
greater length, greater function
The new i150RP wire-draw switch offers
a wire length of up to 75 m. Longer dis-
tances can now be equipped with these
safety switches for protecting extended
areas such as conveyor belts or feed
systems. An emergency stop switch is
integrated in the device thus the emer-
gency stop function is also available at
the end of the wire, doing away with the
need to install a separate emergency
stop switch. The position display and un-
locking lever simplify adjustment of wire
tension. As an option, status can also
be displayed by means of an indicator
light mounted directly on the wire-draw
switch.
Safety switches from SICK an innova-
tive portfolio that is practically oriented
and proven in practice.
The new safety switches and safety locking devices
Safety switches
54 1/2007 54
: Products
Series expanded
3D smart camera now focused
on small parts and pallets
SICK-IVP has expanded its IVC-3D series, still the worlds only 3D smart camera,
with two new variants. The IVC-3D 30 is designed for small and miniature parts,
while the IVC-3D 300 focuses on large objects such as loaded pallets.
>> The IVC-3D 50 and IVC-3D 200 from
SICK-IVP have become quasi-standards
in 3D image processing. The newly pre-
sented IVC-3D 30 variant optimises the
family for small and miniature parts be-
low 65 mm in width. On the other hand,
large objects with widths of up to
1,480 mm (e.g. Europallets) are ide-
ally detected by the new IVC-3D 300.
3D inspection of objects
and checking of features
Both the IVC-3D 30 and the IVD-3D 300
are capable of detecting geometrical
features regardless of their brightness.
Both systems operate with a line of la-
ser light whose reflection is evaluated
in a triangulation process. The laser
optics are integrated within the hous-
insightLINK
INFO 129
ing. This eliminates the need for adjust-
ment and provides a stable, uniform
geometry between the illumination and
camera throughout the entire inspec-
tion process. Both 3D smart cameras
are quickly ready for use thanks to cali-
bration before delivery and data output
in mm.
Precise results at any transport speed
Whether plastic parts or pallets, both
new versions of the IVC-3D combine up
to 5,000 profile sections per second to
form a real 3D image. Height informa-
tion is converted to grey values during
evaluation of the image. The genera-
tion of natural likenesses of the target
objects is also possible, even if they
pass the measurement window at dif-
fering speeds. This poses no problem
for the 3D smart cameras because an
incremental encoder can be connected
for speed or position measurement via
an RS-422 input. Thus objects can be
detected with high precision, even at
fluctuating speeds.
Ideal solutions and ideal alternatives
The IVC-3D 30 and the IVC-3D 300 of-
fer versatile programming and versatile
use. In their particular fields of applica-
tion they represent the ideal solution for
numerous inspection tasks in, among
other areas, the food and packaging
industries, in production processes,
or in robot and handling systems. For
users with expertise in image process-
ing, both 3D smart cameras are flexible
and thanks to the wide-ranging library
with image processing functions indi-
vidually programmable, and represent
extremely cost-effective alternatives to
conventional 3D image processing sys-
tems.
Whether for miniature parts or large pallets the IVC-3D series of smart cameras
offers the right models for the most varied of requirements
Image processing
55 55
: Products
>> The prize-winning safety controllers
of the UE44x7 series, e.g. the UE4427
and the UE4457 with additional Safety
Data Link (SDL) functionality (for the in-
tegration of intelligent SICK safety sen-
sors), allow decentralised IP 67 safety
automation. Their biggest advantage:
direct connection leads to minimum
switching times and thus to a consid-
erable reduction in safety distances on
the machine. The almost explosive rise
in demand for safe IP 67 automation
solutions shows that these arguments
are highly persuasive, and that SICK is
meeting these customer requirements.
With the UE44x7, up to 32 func-
tional modules can be linked to the
IP 67 safety controller from SICK takes first place
A safe winner
The safety controllers of the UE44x7 series from SICK have taken first place in the
well-known GIT Safety Award 2006. They were the clear winners in Category A:
Safe automation in production.
connected safety sensors and actua-
tors to create a decentralised safety
solution. The controller can be used
as a stand-alone device, but network-
ing via the integrated fieldbus interface
allows both safety-oriented signals and
standard signals to be exchanged with
a higher-ranking controller. Using the
enabling principle, standard signals
(e.g. machine start) can influence the
remote IP 67 safety controller via the
central standard controller.
The economical UE44x7 allows im-
plementation of the entire safety func-
tionality in the field without a control
cabinet, directly on the machine or
plant. INFO 128
>> The DFS60 series, which replaces the
successful DGS66, is a new type of in-
cremental hollow-shaft encoder. Any line
number from 1 to 65,536 per rotation is
possible. The encoders electrical insula-
tion between the motor shaft and the en-
coder itself is a feature that significantly
New incremental hollow-shaft encoders for machine and plant construction
All-round innovation and individuality
Flexibility regarding line numbers, improved running properties with vibrations mi-
nimised, electrically insulated hollow-shaft terminals, and a maximum operating
temperature of +100C make the new incremental hollow-shaft encoders of the
DFS60 series trendsetters on the encoder market.
increases availability and immunity to
interference.
High temperature
resistance, excellent running
With its operating temperature range of
between 20C and +100C, the DFS60
series is particularly suitable for applica-
tions involving extreme conditions. A
further improvement involves the quiet
running of the encoder. The separation
of the shaft ball bearings has been in-
creased to 30 mm to achieve excellent
running behaviour, even at operating
rates of 6,000 r.p.m. This also results in
substantially reduced encoder vibration.
The basics are not neglected either,
despite all the DFS60s special features:
hollow shaft diameters of up to 15 mm
with an external housing size of 60 mm,
simple and flexible mounting of custom-
er-specific torque multipliers, universal
cable outlet for radial or axial extension,
and a variety of electrical interfaces (TTL
and HTL) meet the basic prerequisites of
most applications particularly during
use in machine and plant construction.
The new DFS60 series is thus a round-
ed out solution in many ways.
insightLINK
www.sick-stegmann.com and
56 1/2007 56
: Products
Free-moving small transport systems for maximum mobility
Safety guaranteed, navigational
support integrated
Safe mobility is the most important aim of the compact S300 Professional CMS
safety laser scanner. It has been made possible by exploiting the contour data of
the surroundings, detected by the scanner, for navigational support.
>> With a shaft encoder input, and
path- and speed-dependent switchable
protective and warning fields, the S300
Professional safety laser scanner al-
ready offered the important prerequisites
for mobile use. Now the CMS has been
added the integrated Contour Measure-
ment and Safety function. It is based on
the scanners expanded data output and
uses the information to support naviga-
tion. Measurement data for the vehicle
are generated parallel to the safety in-
formation thus, for example, free-mov-
ing transport systems, mobile assembly
plants or autonomous service robots for
industrial use, are not only kept safe but
are also kept on the correct path.
Reflectors as guides
The S300 Professional CMS is capable
of detecting the reflectors as reference
marks within the area of operation. The
area contour is continuously scanned in
real time through a 270 scanning angle.
For each distance value, the navigation
computer also receives information on
the detected reflector marks via the rapid
RS-422 connection (at up to 500 kBaud)
thus achieving precise position determi-
nation. If necessary, the freely selectable
measurement or evaluation area, and the
range of filter options available, permit
optimisation of the data quantity trans-
ferred.
Advantages in a variety
of operating scenarios
The S300 Professional CMS is the ideal
solution for smaller free-moving transport
vehicles. Personal protection and meas-
urement data output integrated in a single
device this cuts sensor and installation
costs. Moreover, producers are not tied
to an expensive complete solution pack-
age, i.e. they can make an independent
selection of the individual components. In
addition to stand-alone use on vehicles,
the S300 Professional CMS is also partic-
ularly suitable in combination with other
path guidance or navigation systems in
order to permit, for example, partially au-
tonomous drive operation. Joint use with
the devices big brother, the S3000 Pro-
fessional CMS, is also possible thanks
to the two scanners compatible telegram
protocols.
SICKs new compact safety laser
scanner, enabled to provide measure-
ment data, meets the requirements of
many vehicle producers who want to
optimise their systems value creation
chain.
insightLINK
INFO 133
Personal protection and measurement data output in a single device
the compact S300 Professional CMS safety laser scanner, the optimum
solution for smaller transport vehicles
Safety laser scanner
Personnel protection and acquisition of
the surrounding contour with
integrated reflector mark detection
57 57
: Museum
On a journey of discovery in the heart of Ireland
The Museum of Birr Castle is located
two hours from Dublin, in the middle of
Ireland. It is an attraction for anyone
interested in landscapes and plants,
technology and photography, or the
early research into the moon and di-
stant star clouds.
>> Birr Castle was originally a 12
th
centu-
ry Norman fortification. The current mu-
seum is based on the one set up by the
third Earl of Rosse in the 1740s. He built
what was then the worlds only giant tel-
escope, with which he studied the moon
and was the first to see distant clouds
of stars such as M27 or Andromeda. The
museums largest feature is still in use
for the daily visitors tour.
Basic research as
industrialisation was starting
In those days Birr Castle also developed
into a type of technological research
institute. Thus a suspension bridge
(which can still be admired today) was
designed and constructed. In the Tech-
nical College, a converted stable, experi-
ments were carried out with steam tur-
bines, electricity and steam-driven flying
machines. Many exhibits illustrate the
wealth of inventions and improvisations
achieved by this researcher. Shortly af-
ter the Frenchman Daguerre developed
the first process for taking photographs,
or Daguerreotypes, the new technology
also moved into Birr Castle. It is thanks
to this that we can now profit from nu-
merous images of the castle, persons
and the landscape.
Botany wherever one looks
Parallel to the technical feats, the coun-
tryside around Birr Castle became one of
combines botany,
technology and early
space research
the most important botanical gardens.
Up to 30,000 visitors a year admire
the variety of plant life on 40 hectares
of land, e.g. more than 1,000 different
types of trees from all over the world, or
a large number of different species of
roses and other flowers. Another attrac-
tion: the waterfall that gives the park its
special flair.
Birr Castle is open daily from
9.00 a m. to 6.00 p.m. All areas can be
visited the Technical College, the giant
telescope, the botanical garden, the Tea
Room, the gift shop and the castle itself
though the latter only from outside,
because the successors to the muse-
ums original founder live within: Lord
and Lady Rosse and their family.
www.birrcastle.com
The impressive giant telescope after restoration
58 58
: SICK Tour
1/2007
SICK Robot Day 2007: slalom
race for autonomous vehicles
Works grounds be-
come pit stop alley
>> SICK AG in Waldkirch takes on the
logistical responsibility for delivery and
stock quality. The goods must be availa-
ble in sufficient numbers and arrive at the
customers facilities in accordance with
the details in the order confirmation. If
one wants to measure reliability and cus-
tomer satisfaction the simple statement
too late is insufficient as a starting
point for making process improvements.
Was the desired delivery unrealistic? Did
the customer change the orders dead-
line? Were there delays in procurement,
production, order picking or preparation
for despatch? All these and more could
lie behind the statement too late.
Approaches for process optimisation
become recognisable
The computer-supported analysis of de-
livery reliability can consider a variety of
causes and thus provide starting points
for process optimisations. The delivery
reliability measurement value provides
information on the order items delivered
at the correct point in time as a per-
centage of the total number of delivery
order items. The reasons for deviations
can be shown both as internal factors
and for individual customers. Changing
of deadlines, insufficient material avail-
ability, exhausted credit limits, or miss-
ing export documentation everything
SICK measures and optimises delivery reliability
Logistical diligence
Its great when one receives ones goods at the agreed time. In order to ensure
that this happens as often as possible, SICK uses specially developed software to
assess its internal process chain, from incoming orders to the despatch of goods.
Delivery reliability is the measure of all things and can be analysed individually
for each customer. Automotive customers will be pleased about its similarity to
ISO/TS 16949.
is visualised and becomes a component
in improvements for, and often with, the
customer.
SICK delivery reliability
leans on ISO TS/16949
ISO/TS 16949 is a specification rec-
ognised worldwide. It is based on
ISO 9001:2000, summarises the re-
quirements of international automobile
producers (many of which were previ-
ously not uniformly worded in North
American and European standards),
and describes what automobile produc-
ers demand of their suppliers corporate
processes. The aim of ISO/TS 16949 is
to effectively improve system and proc-
ess quality in order to increase customer
satisfaction, recognise errors and risks
in the delivery chain, overcome their
causes, and check the effectiveness of
the corrective and preventive measures
introduced. The measurement of SICKs
delivery reliability takes into account the
aims of the standard and implements its
requirements.
The benefits of the measurement of
delivery reliability at SICK are, however,
not restricted to the automotive sector
they are also of advantage to the Eu-
rologistics system, the supply of other
SICK locations and, therefore, to all cus-
tomers in Europe and worldwide.
>> Universities, technical colleges, re-
search institutes and schools they are
all invited to participate in the compa-
nys first slalom race for autonomous
vehicles. SICKs works grounds in Wald-
kirch will become a pit stop alley on
27.10.2007 with vehicles, mechanics,
racing managers and almost everything
that is involved in motor-racing. Only the
drivers camp is missing because there
arent any drivers!
Cash and gift prizes worth over
EUR 4,000 are beckoning
The races in the indoor and outdoor vehi-
cle classes will be carried out in two runs
to determine the fastest. SICK is providing
cash and gift prizes worth over EUR 4,000
for the best teams, those whose vehicles
drive the course (not known until the test
drives) in the shortest time.
A propos provide: SICK is lending
S300 Professional laser scanners to the
participating teams for control and navi-
gation. They will become the property of
the teams if their car is entered.
Dont miss the registration deadline!
So early registration pays. The deadline
for registration is 31 July 2007. Interest-
ed teams can call up the conditions for
participation at www.sick.com and also
register there.
59
>> The Darpa Rally shows SICKs tech-
nological lead in object and vehicle area
detection in two ways: firstly, almost eve-
ry team is relying on current laser scan-
SICK as equipper and participating team
Through wild country unmanned
The Darpa Rally will take place again in the USA in 2007, during which more-or-
less serial unmanned vehicles will find their way through villages and overland.
The winner is already known: laser technology from the SICK Group.
ner technology, e.g. the LMS; secondly,
SICK AG and its Ibeo Automobile Sensor
subsidiary from Hamburg are participat-
ing with their own team of eleven and a
high-tech VW Passat. Three prototypes of
the latest series of laser scanner will be
thoroughly tested in this vehicle called
LUX, and with an appropriate airbrush
design before going into low-volume
production in early 2008.
The Darpa Rally is the perfect opportu-
nity for SICK to measure itself up against
international competitors and the latest
technologies in this, the most extreme
test of autonomous driving. As was the
case last year, the LMS is again the cen-
tral component of most of the area de-
tection systems. The LUX team from Ibeo
Automobile Sensor is using this platform
to prove its serial readiness and the eve-
ryday applicability of its LUX scanner sys-
tems before a wider public.
The winners are those who arrive and
those who have laser safety technology
from SICK on board.
www.team-lux.com www.ibeo-as.com
59
: SICK Tour
>> Simply register and log in under your
individual user name it has never been
as easy to find out where the goods are,
when they will arrive, or who has just
received them. Online delivery tracking
offers all this information and thus a
high level of transparency and planning
security for customers.
And while one is already in the online
portal, why not also look for the solution
for a task that one has long wanted to
clear off ones desk? This is quick and
easy with the Application Finder. Select
the task and/or sector and a list ap-
pears with interesting solution sugges-
tions. Now just one more click and the
Online tracking of deliveries, application searches, documentation
Supplementary online information
at SICK Partner Portal
Its clicking for increasing numbers of SICK customers they are now also obtain-
ing up-to-date delivery information on their orders, finding interesting application
solutions, or selecting documentation on products and solutions from SICK via
mouse-clicks at SICK Partner Portal.
sought-after solution is presented with
all the SICK products involved.
Online in SICK Partner Portal is also
the quickest way to obtain interesting
or important documentation. If a set of
operating instructions has been lost, or
technical information is required, or if one
simply wants to browse through the last
issue of the SICK insight customer maga-
zine the Literature Finder shows all the
available publications and offers them as
.PDF files for downloading.
Has it also clicked for you? Then regis-
ter now at www.mysick.com/register
INFO 134
LUX the high-tech VW Passat with confident colleagues from Hamburg
60 1/2007 60
: SICK Tour
>> In terms of content, the seminars
are designed to meet the interests and
needs of differing participator groups,
e.g. constructors, maintenance staff,
planners, developers or managers.
SICKs team of trainers is supplemented
by external specialists, particularly in
the case of safety-related events. Some
SICK trainers in the areas of standards
and applications are also active in asso-
ciations and on international standardi-
sation committees.
User training now also
sector-specific
In addition to the familiar and proven
courses offered by the Safety Sys-
tems and Auto Ident Divisions, sector-
specific maintenance training for sen-
sors involved in the Industrial Sensors
Division has been included in the pro-
gramme for 2007. There are also new
user training courses on safe control-
lers from SICK.
You want the details?
Then request our training programme or
visit us at www.sick.com/training
By the way: SICK also organises on-site
training, i.e. at your company! Please
contact us. We will then prepare an indi-
vidual offer. INFO 135
>> New on SICKs training team
Rainer Wagner
has many years
experience as a
constructor and project manager in
heavy machine and plant construc-
tion, and as a construction manager
in special machine construction at a
well-known automotive sub-contrac-
tor. Since 2003 he has been active
as a freelance expert on machine and
plant safety, and thus offers the com-
bination of practical experience and
specialist knowledge that is typical of
seminars at SICK. Rainer Wagners
seminars deal with The construction
of safe machines and plant and Car-
rying out redesigns and significant
changes to machines and plant.
Thomas Kraus
from the Ger-
man Engineering
Federation (VDMA) is a member of
the committee responsible for the
EU Machine Directive, the Technical
Equipment and Consumer Products
Committee and the Safety at Work
Committee. He is currently employed
at the Federal Ministry for Trade
and Technology. Together with lawyer
Susanne Jnsch from SICK, he com-
prehensively illuminates the topic of
The Machine Directive and producer
liability for managers.
SICK is again presenting a wide-ranging training programme in 2007 for the Industrial
Sensors, Industrial Safety Systems, and Auto Ident Division. The specialised seminar
that covers the new EN ISO 13849-1 and EN 62061 standards for safe machines is
already being greeted with particular interest early registration is recommended.
Training 2007
Training is preferable to paying for ones mistakes
the programme thats catching on
61 61
: SICK Tour
61
>> This is demonstrated by the events
that have taken place in recent weeks
at, among others, Airbus in Hamburg,
Volkswagens Glazed Manufacturing
Hall in Dresden, at the premises of RWTH
in Aachen and at SICK in Waldkirch. Each
practical afternoon has its own emphasis
in concrete terms, they cover safety and
responsibility, safety and construction,
safety and planning, as well as safety and
maintenance. About 100 people have
participated in the events.
Competent guest speakers
get safety across
One aspect of the talks is to show the
current standards situation in the ar-
ea of safety technology. The fact that
the topic of safety must be considered
comprehensively if one wants to apply
responsible solutions is another impor-
tant aspect. This approach for integrated
safety thinking and action follows SICKs
safetyPLUS
philosophy from the initial

planning stage through the risk analysis,
the application of standards, engineer-
ing, project planning, commissioning
and repair, right up to the modernisation
of a machine. The talks show how inte-
gration, in the form of consistent sen-
sor, control and service solutions from
a single source, lead to economical and
future-oriented results with a high level
After-work talks attract participants
Successful practical safetyPLUS
afternoons
Work in the morning, have lunch, and then attend the companys after-work talks
in the afternoon the idea of SICKs practical safetyPLUS
afternoons is meeting
with lively approval in many companies.
of long-term investment protection. In
a practice-oriented atmosphere, safety
experts from SICK as well as external
guest speakers impart information and
knowledge. These include, among oth-
ers, Gert Eberle, head of the Trade Asso-
ciations R&D (BGFE) training facilities in
Braunschweig, and Dr. Matthias Umbreit
from the Trade Association Metall Sd in
Mainz.
More to come
In the coming weeks and months, SICK
will invite personnel to further after-work
talks involving safetyPLUS
. Those who
want to know where and when can find
out at www.sick.com
www.sick-safetyplus.com INFO 136
>> A small gift here, a nice chat
there, a bit of information over there
one doesnt always have to present
comparatively dry technology in a dry
manner. Some succumbed to the
charms of the ladies in overalls at the
In overalls, all over
Ladies present technologies
(not only) to men
Everybodys talking about IO-Link and safetyPLUS
two campaigns initiated by

SICK that no longer really need any promotion. Though attractively packed informa-
tion cannot do any harm even at the Hanover Trade Fair 2007.
SPS/IPC/DRIVES trade fair. Those who
enjoyed the overall(ed) atmosphere
there, or would like to try out new
developments in attractive packag-
ing, can look forward to the Hanover
Trade Fair 2007
62 62
: Book Corner
>> How do I convince my boss to give
me a pay rise, how do I advocate my
ideas for the project, how do I get a bet-
ter job, how do I best get my message
across to my listeners at meetings or in
speeches, how do I get my point-of-view
across quickly and convincingly? Not at
all straightforward.
Some may have drunk it in with their
mothers milk or learnt it quickly (or have
had to learn it) it is important to keep
what one wants to say short, convincing
and to the point, particularly in ones
business life.
Of course, it is simpler just to get on
with ones work and wait for the great
miracle: that someone recognises ones
brilliant capabilities and then fulfils all
ones wishes. But is ones business life
really like this? Rather seldom. Nowa-
days one must more often fight for what
one wants. Merely doing a good job is
not enough for ones career.
The message that one wants to get
across must be formulated briefly and
meaningfully, and delivered at the right
time that is the skill.
This little book by Milo Frank, an expert
in communication techniques who trav-
elled the world as a trainer for many
years, provides good tips on these mat-
ters. It was specially written for business
training and is intended for anyone who
wants to achieve something in their ca-
reer.
Frank explains why and how one can
use the rules, in almost any situation,
to present your position in 30 seconds
or less. This sounds a bit unbelievable,
but when one reads the book it soon
becomes clear what Frank is aiming
at: formulate the main message clearly
and precisely in advance of a conversa-
tion, presentation or other type of com-
munication so that ones counterpart
listens and can let themselves be con-
vinced.
Frank explains how one achieves this,
e.g. that one must be clear about ones
own aims, know ones listeners and be
aware of what they expect. The core
thoughts must be precisely defined.
There are three basic principles: what
does one want who can provide it
how can one achieve it. Anecdotes,
the right amount of humour, metaphors
and rich imagery help to captivate the
listener.
Clarity of ones statement is very impor-
tant, while maintaining expression and a
personal approach.
What must also not be underestimated
is: the non-verbal impression. How do
I get the message across? Do I read a
speech, for example, (which, by the way,
Frank says should be divided into several
30-second parts) with my head lowered
or do I look the audience squarely in the
eye and smile at them; do I act like I feel,
do I act in such a way that I come over
best: be myself? Credible?
How can I prepare myself for perfect an-
swers to questions that follow a speech
or presentation? How do I behave on
the phone, or what do I record on the
answering machine so that whoever I
have rung will really ring back, how do
I shape a message so that it is actually
read? This and much more is explained
in this book.
At the end of each chapter there is a
box in which everything is summarised
Publisher: Simon & Schuster, 120 pages
ISBN: 0671524925
briefly, and which one really can read in
30 seconds.
And right at the end you find out why Eva
and Charles are still happily married as a
result of a 30-second message.
Summary: the book will probably not
be very informative for those who com-
municate a lot and are well up on their
rhetoric, but it is to be thoroughly recom-
mended for beginners who would like to
perfect their approach. It also offers a lot
of practical examples, though they may
not be the most modern (e-mail is not
mentioned, though it is, in effect, cov-
ered by the tips), and they can be typi-
cally American.
One more comment on this point: as
SICK insight is an international magazine
with a print run of over 60,000 it is, of
course, translated into English so that
we always have to select books that are
available in both German and English
and these are almost all books by Ameri-
can authors. We would be delighted to
hear from you if you have any alternative
tips for us!
1/2007
This Book Corner is written by
Online Editor Ingrid Rathfelder
63 63 63
: Standards
63
insightLINK
Weitere Infos erhalten Sie mit der
Karte am Ende des Magazins unter:
INFO 121
insightSERVICE
Imprint
Publisher: SICK AG Postfach 310 79177 Waldkirch Germany www.sick.com
Phone +49 7681 202-0 Fax +49 7681 202-38 63 info@sick.de
Co-ordination: Anette Gasche Customer Magazine Project Manager Anette.Gasche@sick.de
Specialist editor: TOP MEDIA Dirk S. Heyden 69469 Weinheim info@topmedia-weinheim.de
Layout: johnson][braun Direktwerbung 76133 Karlsruhe jb@johnsonbraun.de
Translator: Richard Dennis 79194 Gundelfingen richarddennis@t-online.de
Printing: Druckerei Furtwngler 79211 Denzlingen info@druckerei-furtwaengler.de
Pictures: SICK AG, Auslser Fotodesign, Krieg Fotodesign, Birr Castle, Biba, Cesag
Individual contributions may be reproduced after prior consent. Please contact us at:
Phone +49 7681 202-3878 Errors excepted Subject to technical change
SICK Vertriebs-GmbH
Schiessstr. 56
40549 Dsseldorf
Germany
Phone +49 211 53 01-0
Fax +49 211 53 01-100
e-mail info@sick.de
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Phone +49 7681 202-0
Fax +49 7681 202-38 63
e-mail info@sick.de
Trade fair dates Germany
Trade Fair Location Dates 2007
Hanover Trade Fair Hanover 16.04. 20.04.2007
Control Sinsheim 08.05. 11.05.2007
A + A Dsseldorf 18.09. 21.09.2007
Motek Stuttgart 24.09. 27.09.2007
Semicon Stuttgart 09.10. 11.10.2007
VISION Stuttgart 06.11. 08.11.2007
PRODUCTRONICA Munich 13.11. 16.11.2007
SPS/IPC/DRIVES Nuremberg 27.11. 29.11.2007
Trade fair dates Europe
EmCERTS Bretby, UK 25.04. 26.04.2007
Gas Expo Kielce, PL 25.04. 26.04.2007
Intec Dornbirn, A 03.05. 05.05.2007
World Tunnel Congress Prague, CZ 07.05. 09.05.2007
Safety&Security Amsterdam, NL 08.05. 10.05.2007
Tehnika Belgrade, SRB 08.05. 12.05.2007
MEC Venice, I 09.05. 11.05.2007
ANIPLA Milan, I 10.05. 11.05.2007
Total Processing&Pack Birmingham, UK 15.05. 18.05.2009
Vision Robotics Ede, NL 12.06. 13.06.2007
Pharmintech Bologna, I 12.06. 14.06.2007
go.automation technology Basel, CH 04.09. 07.09.2007
Eltech Plovdiv, BG 24.09. 29.09.2007
Post Expo Barcelona, E 02.10. 04.10.2007
M&R Brussels, B 14.10.2007
Groothandel & Logistiek Utrecht, NL 30.10. 01.11.2007
Community & Security Utrecht, NL 30.10. 01.11.2007
Trade fair dates worldwide
Oil & Gas Teheran, Iran 18.04. 22.04.2007
Asian Oil&Gas Kuala Lumpur, MAL 13.05. 15.05.2007
KOFAS Changwon, KOR 16.05. 19.05.2007
Environmental Techn. Seoul, KOR 11.06. 14.06.2007
Robots & Vision Show Rosemont, USA 12.06. 14.06.2007
TOC Istanbul, TR 19.06. 21.06.2007
FABTECH Chicago, USA 11.11. 14.11.2007
Trade fairs Imprint Contacts
Subsidiaries
Australia
Phone +61 3 9497 4100
+1800 3 3480 2 tollfree
sales@sick.com.au
Austria
Phone +43 22 36 62 28 8-0
office@sick.at
Belgium/Luxembourg
Phone +32 2 466 55 66
info@sick.be
Brazil
Phone +55 3215 4900
sac@sick.com.br
China
Phone +852 2763 6966
ghk@sick.com.hk
Czech Republic
Phone +420 2 57 91 18 50
sick@sick.cz
Denmark
Phone +45 45 82 64 00
sick@sick.dk
Finland
Phone +358 9-25 15 800
sick@sick.fi
France
Phone +33 1 64 62 35 00
info@sick.fr
United Kingdom
Phone +44 17 27-83 11 21
info@sick.co.uk
India
Phone +91 22 2822 7084
info@sick-india.com
Italy
Phone +39 02 27 43 41
info@sick.it
Japan
Phone +81 3 3358 1341
support@sick.jp
Netherlands
Phone +31 30 229 25 44
info@sick.nl
Norway
Phone +47 67 81 50 00
austefjord@sick.no
Poland
Phone +48 22 837 40 50
info@sick.pl
Republic of Korea
Phone +82 2 786 6321/4
kang@sickkorea.net
Russia
Phone +7-495-775-05-34
denis.kesaev@sick-automation.ru
Singapore
Phone +65 6744 3732
admin@sicksgp.com.sg
Slovenia
Phone +386 (0)11-47 69 990
office@sick.si
Spain
Phone +34 93 480 31 00
info@sick.es
Sweden
Phone +46 10 110 10 00
info@sick.se
Switzerland
Phone +41 41 619 29 39
contact@sick.ch
Taiwan
Phone +886 2 2365 6292
sickgrc@ms6.hinet.net
Turkey
Phone +90 216 587 7400
info@sick.com.tr
USA
Phone +1 (952) 941 6780
info@sickusa.com
More at www.sick.com

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01 2007 www.sick.

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